Radial riveting machine RNE 381 - baltecorporation.com

BalTec Maschinenbau AG Obermattstrasse 65 CH - 8330 Pfäffikon ZH Phone: +41 (0)44 953 13 33 Fax: +41 (0)44 953 13 44 [email protected] http:\\www.baltec.com

OPERATING INSTRUCTIONS

Radial riveting machine RNE 381 without Control 803858.010/ENG

Machine no.

xxx.xxxx

Power supply

xxx

803858.010/ENG

Introduction

2

Radial riveting machine RNE 381

803858.010/ENG


Introduction

Contents 1

Introduction ............................................................................................................... 6

2

Safety regulations ..................................................................................................... 7

2.1 2.2 2.3 2.3.1 2.3.2 2.4 2.5 2.5.1 2.5.2 2.5.3 2.6 2.7 2.8 2.9

3 3.1 3.2 3.3 3.4 3.5

4 4.1 4.1.1 4.2

5 5.1 5.1.1 5.1.2 5.1.3 5.1.1 5.2 5.2.1 5.2.2 5.2.3 5.3 5.4

6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

Term definitions ...................................................................................................................................7 Significance of the safety regulations .................................................................................................7 Information and symbols .....................................................................................................................8 Warning and safety notices ............................................................................................................8 Notes and symbols on the product ................................................................................................9 Application limitations ..........................................................................................................................9 Intended use .....................................................................................................................................10 Riveting machine/riveting unit ......................................................................................................10 Form tool ......................................................................................................................................10 Workpiece holders .......................................................................................................................11 Emissions ..........................................................................................................................................11 Power supply .....................................................................................................................................11 General safety rules ..........................................................................................................................12 Declarations ......................................................................................................................................12

Product description ................................................................................................ 13 RNE 381 details ................................................................................................................................13 Hydraulic aggregate RNE 381 details ...............................................................................................14 Dimensions drawing RNE 381 ..........................................................................................................15 Dimensions drawing RNE 381 for flange mounting ..........................................................................16 Technical specifications riveting machine 381 ..................................................................................17

Commissioning ....................................................................................................... 18 Introduction........................................................................................................................................18 Personnel requirements ...............................................................................................................18 Riveting unit ......................................................................................................................................18

Operation ................................................................................................................. 19 Safety regulations riveting machine ..................................................................................................19 Personal safety equipment ..........................................................................................................19 Workplace ....................................................................................................................................19 Heating of riveting machine .........................................................................................................19 Heating of hydraulic aggregate ....................................................................................................19 Basic settings ....................................................................................................................................20 Riveting stroke adjustment ...........................................................................................................20 Riveting spindle advance speed adjustment ...............................................................................20 Riveting force adjustment ............................................................................................................21 Setting up the riveting machine for a new workpiece .......................................................................22 Possible machine settings.................................................................................................................23

Form tools ............................................................................................................... 24 Form tool designs and closing head shapes .....................................................................................24 Recommended form tool materials ...................................................................................................25 Form tool D = 20 with various lengths...............................................................................................26 Replacing the form tool holder and pressure cup .............................................................................28 Replacing the pressure cup with the removal device .......................................................................30 Standard form tool Ø20 with flat profile (270-431) ............................................................................31 Standard form tool Ø20 with conical profile (270-431) .....................................................................32 Standard form tool Ø20 with crowned profile (270-431) ...................................................................33

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3

Introduction 7 7.1 7.1.1 7.1.2 7.2 7.3 7.3.1 7.3.2 7.3.3 7.4 7.5

8 8.1 8.1.1 8.1.2 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.3

9


Options .................................................................................................................... 34 Pressure pad .................................................................................................................................... 34 Pressure pad dimensions drawing .............................................................................................. 35 Production of thrust piece and spring diagram 802296 .............................................................. 36 Automatic lubrication riveting spindle head ...................................................................................... 38 Foot switch ....................................................................................................................................... 39 Function ....................................................................................................................................... 39 Dimensions drawing .................................................................................................................... 39 Technical specifications .............................................................................................................. 40 Initiator upper end position ............................................................................................................... 41 Initiator lower end position (bridging initiator) ................................................................................... 41

Maintenance and repair work ................................................................................ 42 Introduction ....................................................................................................................................... 42 Safety regulations ........................................................................................................................ 42 Personnel requirements .............................................................................................................. 42 Overview of maintenance work ........................................................................................................ 43 Riveting spindle head (form tool holder and pressure cup) ........................................................ 44 Riveting spindle ........................................................................................................................... 45 Automatic lubrication riveting spindle head (option) ................................................................... 47 Hydraulic aggregate .................................................................................................................... 48 Polygon shaft............................................................................................................................... 50 Two-hand operating unit ............................................................................................................. 51 Piston and piston rod seals ......................................................................................................... 51 Riveting motor terminal box ........................................................................................................ 52 Maintenance and repair log .............................................................................................................. 53

Decommissioning, Storage.................................................................................... 55

9.1 9.2 9.3

Decommissioning ............................................................................................................................. 55 Storage ............................................................................................................................................. 55 Re-commissioning ............................................................................................................................ 55

10

Disposal ................................................................................................................... 56

10.1 10.1.1 10.2 10.2.1 10.2.2 10.2.3

11 11.1 11.1.1 11.1.2 11.2 11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.2.6 11.2.7 11.2.8 11.2.9

12

4

Introduction ....................................................................................................................................... 56 Personnel requirements .............................................................................................................. 56 Disposal ............................................................................................................................................ 56 Replaced parts ............................................................................................................................ 56 Mineral oils .................................................................................................................................. 56 Riveting unit ................................................................................................................................. 56

Appendix ................................................................................................................. 57 Schemata ......................................................................................................................................... 57 Hydraulic diagram 381 801949-d ................................................................................................ 57 Pneumatic diagram for automatic lubrication 802417 ................................................................. 58 Spare parts lists ................................................................................................................................ 59 Machine body 381 Standard/HPP 852401-b .............................................................................. 59 Riveting head 270-431 838310-k ................................................................................................ 65 Electric motor 381 852320-k ....................................................................................................... 67 Automatic lubrication 814340-u ................................................................................................... 68 Foot switch 813345-d .................................................................................................................. 70 Two-hand operating unit 814350-d ............................................................................................. 71 Pressure pad 270-431 838315-g ................................................................................................ 72 Hydraulic aggregate RNE 381 852435-q .................................................................................... 74 Pressure transmitters fixing 852070-e ........................................................................................ 76

Index ........................................................................................................................ 79

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Introduction

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5

Introduction 1


Introduction We are certain that you have made the right choice with our product and thank you for your trust. For your personal safety Before carrying out any activities on or with the riveting machine, please carefully read these operating instructions first, in particular the chapter on "Safety regulations". Application area of these operating instructions These operating instructions describe the riveting machine and provide all information required for safe operation and maintenance of functionality. Please keep these operation instructions available at all times for all persons involved with the riveting machine. Questions or unclear points Please contact immediately if you have any questions or unclear points: - BalTec Maschinenbau AG, Obermattstrasse 65 CH – 8330 Pfäffikon ZH - BalTec – distributors (see representatives list in the appendix) Please provide them with the document and page numbers located in the footer and the machine number listed on the title page of operating instructions. Original language of assembly instructions These assembly instructions was originally written in German language. —— © Copyright BalTec Maschinenbau AG – Pfäffikon 2010

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2 2.1

Safety regulations

Safety regulations Term definitions The following terms are used with regards to safety: Personnel qualification The work to be implemented with or on the product is described in the corresponding chapters in the operating instructions. The personnel qualifications listed in this chapter (in "Introduction") describes the minimum requirements for personnel regarding training and competences for implementing this work. Personnel Personnel are people who meet the personnel qualifications. Only such personnel are authorized to implement the work described in the applicable chapters. User Users are persons who cannot be identified as personnel but who still carry out activities with or on the product. Operator The operator is the owner of the product. This is irrespective of whether the product is: 

Operated as a stand-alone machine



Operated as part of a system or

 Operated by a third party Product life phases The product life phases are the state or usage phases of the product. These range from leaving the assembly hall to disassembly and disposal, and are divided into correspondingly logical sections (chapters) in these operating instructions. 2.2

Significance of the safety regulations These safety regulations contain all behavior regulations and generally applicable danger information. The safety of the user and the personnel can only be ensured when these safety regulations and the safety information listed in the individual chapters are strictly complied with and followed. The operator is responsible for the enforcement.

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7

Safety regulations

2.3 2.3.1


Information and symbols Warning and safety notices The warning and safety notices used in these operating instructions have the following significance:

CAUTION Indicates a hazard with low risk which, if not avoided, could result in minor or moderate injury.

WARNING Indicates a possible hazard with medium risk which, if not avoided, could result in death or serious injury.

DANGER Indicates an immediate hazard with high risk which, if not avoided, will result in death or serious injury.

NOTICE Indicates practical information and tips that permit the best use of machinery, system or equipment.

CAUTION To warn of material damage only.

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2.3.2

Safety regulations

Notes and symbols on the product The following information and symbols are located on the riveting machine: Warning signs Danger of hand injuries

2.4

Mandatory sign Wear safety goggles

Mandatory sign Wear gloves

Application limitations The following technical operating instructions and ambient conditions must be complied with for the operation of the riveting machine. Environmental conditions Working temperature

+10 ... +50 °C

Storage temperature

- 10 ... +70 °C

Relative humidity

Max. 90%, non-condensing

Mechanical power supply Operating pressure

See technical specifications, label

Rivet parameters Riveting force


Rivet diameter

See technical specifications

Electrical power supply Rated voltage

See title page, label

Rated current


Frequency

See title page, label

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9

Safety regulations

2.5 2.5.1


Intended use Riveting machine/riveting unit BalTec riveting machines are intended to form positive connections by cold forming of connection elements. The connection element (rivet) can either be a separate element or a specially shaped deformation zone on the workpiece itself. The connection is created in that a riveting tool (form tool) creates a closing head on the connection element. Following activation types are permitted to actuate the riveting process: a) Permanent activation with two-hand switching for: 

Manual charging



Stroke H greater than 6 mm



Stroke speed greater than 30 mm/s

b) Pulse actuation with any command device (e.g. foot switch), where one of the following conditions is met: 

Workpiece charging with handling device



Stroke H smaller than 6 mm



Stroke speed smaller than 30 mm/s

The riveting machines are laid out for use in commercial or industrial production; e.g. a) As machining station in a production line b) As stand-alone workplace or production cell The riveting units are laid out for installation in any spatial position: e.g. a) Vertical, with direction of action from top to bottom or bottom to top b) Horizontal 2.5.2

Form tool

WARNING Form tool breaks if an inappropriate material is used! Eye injuries, cutting damages! Form tool is to produce according to our specifications: material, heat treatment, geometry (see Chapter "Form tools").

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2.5.3

Safety regulations

Workpiece holders

WARNING Workpiece can be catapulted out! Eye injuries, cutting damages! Workpiece holders must be securely mounted on the machine table, e.g. with T-slots-screws, clamping shoes or other suitable and secure clamping equipment.

2.6

Emissions Noise The sound pressure level of noise produced by BalTec riveting machines at the operator's workplace is less than 70 dB(A) (measured according to SN EN ISO 3746). Vibrations Vibrations may be caused by the riveting machines dependent on the BalTec riveting process. Suitable vibration damping measures are required where other system parts may start oscillating due to resonance.

2.7

Power supply

DANGER Electrical hazard! Electric shock! Before the machine or their components are connected, isolate the electrical power supply and secure against being switched on again!

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11

Safety regulations

2.8


General safety rules Modifications Modifications to the riveting machine or control unit, in the sense of attachments and conversions are only permissible after prior consultation with and written authorization from the manufacturer. This also applies to welding on load-bearing components and the attachment of control, supply and transfer systems from third party suppliers.

2.9

Declarations CE conformity declaration A CE-compliant riveting machine is marked with a CE rating plate. The standards used to check conformity are listed in the CE conformity declaration. The CE conformity declaration is included in the delivery documentation. Declaration of incorporation When being installed in other machines and/or for operation with a third party control unit, a non CE-compliant riveting machine cannot be commissioned until it is ensured that it meets the provisions of the machine directive 2006/42/EG. The declaration of incorporation is included in the delivery documentation.

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3

Product description

Product description

3.1

RNE 381 details

Item

Name

Item

Name

1

Riveting stroke adjustment

6

Riveting spindle head

2

Clamping screw for riveting stroke adjustment

7

Form tool

3

Lubricator nipple

17

Initiator lower end position (option)

4

Hydraulic connection riveting spindle advance

21

Initiator upper end position (option)

5

Hydraulic connection riveting spindle return

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Product description

3.2


Hydraulic aggregate RNE 381 details

Item

Name

Item

Name

1

Electric motor

7

Return line filter with aerating filter

2

Intermediate flange

8

Magnetic valve

3

Oil tank

9

Pressure regulator valve

4

Oil filler

11

Oil level indicator

5

Manometer

12

Connecting thread R 3/8“

6

Valve manifold

14

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3.3

Product description

Dimensions drawing RNE 381 Drawing no. 852400.30

Free height „H“ see chapter ”Form tool D=20 with various lengths“

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15

Product description

3.4


Dimensions drawing RNE 381 for flange mounting Drawing no. 852400.34

Free height „H“ see chapter ”Form tool D=20 with various lengths“

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3.5

Product description

Technical specifications riveting machine 381 Maximum rivet shaft diameter (solid shaft rivet, steel 2 370 N/mm )

Ø

20

Riveting unit motor, driving power at 50Hz

kW

1.1

Riveting unit motor, driving power at 60Hz

kW

Riveting unit motor, rpm at 50Hz

1.1 -1

1390

-1

min

Riveting unit motor, rpm at 60Hz

min

1660

Hydraulic aggregate motor, -1 Driving power at 1500 min and 50Hz

kW

1.1

Hydraulic aggregate motor, -1 Driving power at 1800 min and 60Hz

kW

1.27

Rated current riveting unit motor at 3 x 220V

A

6.5


A

4.0


A

3.5

Rated current hydraulic aggregate motor

A

2.7

Hydraulics operating pressure

bar

10 - 65

Max. output hydraulic pump at 50Hz

l/min

8.7

Max. output hydraulic pump at 60Hz

l/min

10.4

Max. riveting force

kN

40

Max. permissible riveting time per cycle

sec

10

Tool stroke (stroke limiting stop-adjustment range)

mm

5 - 50

Weight of riveting machine without control unit

kg

200

Weight of riveting machine with control unit

kg

210

Weight of riveting unit

kg

80

Weight of hydraulic aggregate empty

kg

54

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17

Commissioning

4


Commissioning

4.1 4.1.1

Introduction Personnel requirements Commissioning work must be implemented by persons who have mechanical and electrical training. The connection of electrical component has to be made only by a trained authorised electrician.

4.2

Riveting unit The necessary information for commissioning are indicated in the assembly instructions.

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5

Operation

Operation

5.1 5.1.1

Safety regulations riveting machine Personal safety equipment All user are obliged to wear the following personal safety equipment for all work:   

5.1.2

Tightly fitting working clothes Safety goggles Gloves

Workplace The riveting machine may only be operated by one person.

CAUTION Third party can hold fingers between form tool and workpiece! Danger of hand injuries! Configure workplace with rivet holder so that third parties do not have access (e.g. three-sided enclosure) 5.1.3

Heating of riveting machine Forming procedures can lead to heating.

CAUTION Riveting head, tool and workpiece could be hot! Light burns! Do not touch with unprotected hand! 5.1.1

Heating of hydraulic aggregate Parts on the hydraulic aggregate heat during operation.

CAUTION Heated parts on hydraulic aggregate! Light burns! Do not touch with unprotected hand!

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19

Operation

5.2 5.2.1


Basic settings Riveting stroke adjustment The maximum possible riveting stroke can be set with the riveting stroke adjustment. Item

Name

1

Clamping screw (UK) / Clamping bolt (US)

2

Adjustment ring

Procedure: 1. Undo the clamping screw 2. Adjust stroke by turning the adjustment ring: Rotate to the right: Stroke is reduced Rotate to the left: Stroke is increased 3. Value on the scale roughly represents the stroke up to the stop 4. Retighten clamping screw

NOTICE Only tighten the clamping screw lightly to avoid damaging the clamping band! 5.2.2

Riveting spindle advance speed adjustment The advance speed of the riveting spindle is approx. 2.5 m/min. (1.64 inch/sec.) and can be reduced via the non-return valve sandwich at the hydraulic aggregate

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5.2.3

Operation

Riveting force adjustment The riveting force (operating pressure) is adjusted at the pressure regulator valve on the housing that is mounted under the control-box support or at the pressure regulator valve of the hydraulic aggregate. The operating pressure set determines the riveting force at the form tool (see pressure/force diagram). Pressure/Force diagram

70

60

P [bar]

50

40

30

20

10

0 0

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

36

38

40

F [kN]

P = operating pressure

F = riveting force

NOTICE The operating pressure can be set between 10 - 65 bar. The maximum operating pressure is 65 bar and must not be exceeded!

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21

Operation

5.3


Setting up the riveting machine for a new workpiece Before setting up for a new riveting job, the following requirements must be met: 1. Suitable form tool for the rivet and closing head to be produced 2. Form tool length suitable for calotte radius of pressure cup (Rp) in the currently installed form tool holder

NOTICE The form tool length Ls must be selected so that the form-shaping form tool profile cuts directly in the radius centerpoint (see Chapter "Form tools"). 3.

Rivet holder or workpiece carrier must be set up centrically to the riveting spindle axis and fixed onto the machine table The following settings must always be made in the control unit "Setup operation" so that the procedure can be interrupted at any time: 1. Insert workpiece 2. Adjust the height of the riveting machine in the stand so that the distance of the form tool to the rivet is smaller than the maximum achievable spindle stroke. If a short cycle time is desired, this distance to the workpiece can be reduced as long as the necessary distance required to insert the workpiece is maintained. 3. Set the required dimension for the rivet path with the stroke limiting stop

NOTICE Incrementally lower the stroke limiting ring to determine the correct setting using a test workpiece. 4.

At the same time, incrementally adjust the riveting force setting (via pressure regulator) and riveting spindle advance speed (via restrictor valve) to obtain the required results If the workpieces evidence spreading over the height, the stroke limitation may be an obstacle. In this case, the stroke limiting stop should be set slightly lower than necessary. The actual riveting path is then only limited by the termination of the specified riveting time.

NOTICE If other system parts may start oscillating due to resonance by the riveting process, check that the tool is in perfect condition and that the workpiece holder is fastened without any play.

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5.4

Operation

Possible machine settings Riveting to stroke limiting stop Suitable for workpieces with constant thickness. The necessary riveting path can be finely set by adjusting the stroke limiting stop. The height of the closing head then only spreads by the workpiece height spread value. The riveting time must therefore be sufficient that the stroke limiting stop is also securely reached. During the "riveting out" on the stroke limiting stop, stress is removed and the closing head is cleanly smoothed. Riveting without stroke limiting stop Suitable for parts with differing heights. Instead of a limiting stop, the stroke is limited by the set riveting time. The closing head is then only influenced by the pressure, stroke speed (exhaust valve throttle) and the riveting time. The stroke limitation must be set so that the form tool cannot move into the workpiece carrier when a workpiece is not present. Riveting under high pressure Suitable for rivets where a high hole intrados pressure is required. If a higher pressure is selected for a specific riveting, the riveting time is reduced. The permissible pressure limit is set by the workpiece itself. The opening of the restrictor valve means both a faster advance of the riveting spindle (centre sleeve) and a steeper rise in force. Riveting under low pressure Suitable for joint riveting. A longer riveting time, but lower pressure. The stress on the workpiece is reduced. Possible bending of a rivet pin can be prevented. The partial closing of the restrictor valve also works in the same direction. Advance speed and rise in force takes place slowly. Less material is pressed into the bore, the closing head therefore has more material volume available and will tend to be larger, the intrados remains small.

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23

Form tools

6 6.1


Form tools Form tool designs and closing head shapes The shape of the closing head being produced depends on the design of the form tool.

Dimensions for DS and LS, see the lists "Standard form tools".

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6.2

Form tools

Recommended form tool materials Table 1

Material

DIN Name

Material no.

Max. hardness

heat treatment Hardening

Annealing

90 Mn V8

1.2842

63-65 HRC

800-850 C

100-300 C

Analysis C %

Si %

Mn %

P

S

%

%

Cr %

V %

0.85-0.95

0.15-0.30

1.90-2.10

0.030

0.030

0.20-0.50

0.05-0.15

Application

Preparation commercial rivet materials

Form tool designs

Normal and special designs Table 2

Material

DIN Name

Material no.

Max. hardness

heat treatment Hardening

Annealing

S 6-5-2

1.3343

64-66 HRC

1190-1240 C

540-560 C

Analysis C %

Si %

Mn %

P

S

%

%

0.840.92

0.45

0.40

0.030

0.030

Application

Preparation tempered materials

Form tool designs

Normal and special designs

803858.010/ENG

Cr %

Mon. %

V %

W %

3.804.50

4.705.20

1.702.00

6.006.70

25

Form tools

6.3


Form tool D = 20 with various lengths Standard form tools with shaft diameter Ds = 20mm must be removed using the removal tool (BalTec order no. 838185) that is supplied with the machine accessories (see instructions below) but they can be reinserted manually. They are held with 3 suspension thrust pieces. Procedure: 1.

Form tool in installed condition

2.

Undoing the form tool:



Insert removal device in groove



Lever removal device upwards until the form tool loosens

3.

Pull form tool downwards

CAUTION Longer form tools require the replacement of the form tool holder and pressure cup. Form tool length must always be in combination with pressure cup and form tool holder as shown in the table below. Non-compliance can lead to the destruction of the machine!

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Form tools

Item

Name

1

Form tool axis

2

Pressure cup

3

Form tool holder

4

3 thrust pieces

5

Form tool Machines Type

Radius Rp [mm]

270 281 331 381

100 116 132 148

Form tool length Ls [mm ± 0.1] 68 84 100 116

803858.010/ENG

Shaft  Ds [mm]

Angle 

20g6

5° 37´ 4° 47´ 4° 10´ 3° 41´

Free height H [mm] 28 44 60 76

27

Form tools

6.4


Replacing the form tool holder and pressure cup

Item

Name

1

Internal ring gear

2

Pressure cup

3

Form tool holder

4

Connection piece

5

Screw M4x12

6

Pressure spring

7

Cap

8

Form tool

Procedure: 1. 2.

Pull form tool out of riveting head Undo the screws with which the cap is fastened

CAUTION The cap is under spring pressure! Cap and form tool holder fall on the fingers! Gloves are mandatory!

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3. 4.

Form tools

Once the cap is removed, pull the form tool holder and pressure spring out of the riveting head Pull the pressure cup out of the centring in the connection piece using the screws M5x70 provided in the machine accessories and insert a new pressure cup

CAUTION The screws M5x70 must not be used to push the pressure cup off the internal ring gear. Contact surface of internal ring gear will be damaged! 5. 6.

Grease the form tool holder with Klübersynt GE 46-1200 (also see Chapter "Maintenance and repair work") Once the new pressure cup is inserted, hold the cap with the form tool holder and pressure spring pressed against the pressure cup. Screw cap back on

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29

Form tools

6.5


Replacing the pressure cup with the removal device The form tool holder and pressure cup can be most easily removed using the removal device shown below. This is available as an option from BalTec (order no. 865893).

Item

Name

1

Removal device

2

Internal ring gear

3

Pressure cup

4

Special screws M5x120

5

Connection piece

CAUTION The special screws M5x120 must not be used to push the pressure cup off the internal ring gear. Contact surface of internal ring gear will be damaged!

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6.6

Form tools

Standard form tool Ø20 with flat profile (270-431)

Ls = 68 ± 0.1 Articleno. 883121** 883122 883123** 883124 883125** 883126 883001* 883002 883003* 883004 883005* 883006 883007* 883008 883009* 883010 883011* 883012 883013* 883014 883015* 883016 883017* 883018 883019* 883020 883021* 883022 883023* 883024 883025* 883026 883027* 883028 883029* 883030 883031* 883032 883033* 883034 883035* 883036 883037* 883038 883039* 883040 883041*

Øds ± 0.1

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0 20.5 21.0 21.5 22.0 22.5 23.0 23.5 24.0 24.5 25.0

α°

Ls = 84 ± 0.1 L2

L3

25-45 25-45 25-45 25-45 25-45 25-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45

Articleno. 883127 883128 883129 883130 883131 883132 883042 883043 883044 883045 883046 883047 883048 883049 883050 883051 883052 883053 883054 883055 883056 883057 883058 883059 883060 883061 883062 883063 883064 883065 883066 883067 883068 883069 883070 883071 883072

39 39 39 39 39 39 39 39 39 39

42 42 42 42 42 42 42 42 42 42

Øds ± 0.1

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0

α°

Ls = 100 ± 0.1 L2

L3

25-45 25-45 25-45 25-45 25-45 25-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45

Articleno. 883133 883134 883135 883136 883137 883138 883081 883082 883083 883084 883085 883086 883087 883088 883089 883090 883091 883092 883093 883094 883095 883096 883097 883098 883099 883100 883101 883102 883103

Øds ± 0.1

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0

α°

L2

L3

25-45 25-45 25-45 25-45 25-45 25-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45

* = available from stock (α = 15°) ** = available from stock (α = 25°)

803858.010/ENG

31

Form tools

6.7


Standard form tool Ø20 with conical profile (270-431)

Ls = 68 ± 0.1 Article no.

Øds

884121** 884122 884123** 884124 884125** 884126 884001* 884002 884003* 884004 884005* 884006 884007* 884008 884009* 884010 884011* 884012 884013* 884014 884015* 884016 884017* 884018 884019* 884020 884021* 884022 884023* 884024 884025* 884026 884027* 884028 884029* 884030 884031* 884032 884033* 884034 884035* 884036 884037* 884038 884039* 884040 884041*

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0 20.5 21.0 21.5 22.0 22.5 23.0 23.5 24.0 24.5 25.0

32

± 0.1

α° 25-45 25-45 25-45 25-45 25-45 25-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45

β° ± 30’

5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

Ls = 84 ± 0.1 Rs 5.7 7.2 8.6 10.0 11.5 12.9 14.3 15.8 17.2 18.6 20.1 21.5 22.9 24.4 25.8 27.3 28.7 30.1 31.6 33.0 34.4 35.9 37.3 38.7 40.2 41.6 43.0 44.5 45.9 47.3 48.8 50.2 51.6 53.1 54.5 55.9 57.4 58.8 60.2 61.7 63.1 64.5 66.0 67.4 68.8 70.3 71.7

L2 L3

Article no. 884127 884128 884129 884130 884131 884132 884042 884043 884044 884045 884046 884047 884048 884049 884050 884051 884052 884053 884054 884055 884056 884057 884058 884059 884060 884061 884062 884063 884064 884065 884066 884067 884068 884069 884070 884071 884072

39 39 39 39 39 39 39 39 39 39

42 42 42 42 42 42 42 42 42 42

Øds ± 0.1

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0

α° 25-45 25-45 25-45 25-45 25-45 25-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45

β° ± 30’

4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5

Ls = 100 ± 0.1 Rs

L2 L3

6.4 8.0 9.6 11.2 12.7 14.3 15.9 17.5 19.1 20.7 22.3 23.9 25.5 27.1 28.7 30.3 31.9 33.5 35.1 36.6 38.2 39.8 41.4 43.0 44.6 46.2 47.8 49.4 51.0 52.6 54.2 55.8 57.4 58.9 60.5 62.1 63.7

* = available from stock (α = 15°) ** = available from stock (α = 25°)

803858.010/ENG

Article no. 884133 884134 884135 884136 884137 884138 884081 884082 884083 884084 884085 884086 884087 884088 884089 884090 884091 884092 884093 884094 884095 884096 884097 884098 884099 884100 884101 884102 884103

Øds ± 0.1

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0

α° 25-45 25-45 25-45 25-45 25-45 25-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45

β° ± 30’

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

Rs 7.2 9.0 10.8 12.5 14.3 16.1 17.9 19.7 21.5 23.3 25.1 26.9 28.7 30.5 32.3 34.0 35.8 37.6 39.4 41.2 43.0 44.8 46.6 48.4 50.2 52.0 53.8 55.6 57.3

L2 L3


6.8

Form tools

Standard form tool Ø20 with crowned profile (270-431)

Ls = 68 ± 0.1 Article no.

Øds ± 0.1 +

885121 885122 885123+ 885124 885125+ 885126 885001* 885002 885003* 885004 885005* 885006 885007* 885008 885009* 885010 885011* 885012 885013* 885014 885015* 885016 885017* 885018 885019* 885020 885021* 885022 885023* 885024 885025* 885026 885027* 885028 885029* 885030 885031* 885032 885033* 885034 885035* 885036 885037* 885038 885039* 885040 885041*

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0 20.5 21.0 21.5 22.0 22.5 23.0 23.5 24.0 24.5 25.0

α°

25-45 25-45 25-45 25-45 25-45 25-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45

Ls = 84 ± 0.1

Ro

Bt

± 0.1

± 0.05

3.3 3.0 4.8 4.3 6.6 5.5 5.7 6.3 7.0 7.8 8.5 9.0 9.8 10.5 11.2 12.0 12.6 13.4 14.2 15.0 15.7 16.5 17.3 18.0 18.9 19.7 20.5 21.5 22.3 23.1 24.0 25.0 25.8 26.8 27.6 28.6 29.4 30.4 31.5 32.4 33.5 34.5 35.5 36.6 37.6 38.8 39.8

0.10 0.27 0.18 0.38 0.25 0.48 0.47 0.52 0.57 0.60 0.65 0.71 0.75 0.80 0.84 0.88 0.93 0.97 1.01 1.05 1.10 1.13 1.17 1.22 1.25 1.29 1.33 1.36 1.39 1.43 1.47 1.49 1.53 1.56 1.60 1.63 1.65 1.68 1.70 1.73 1.76 1.79 1.82 1.84 1.87 1.89 1.92

L2

39 39 39 39 39 39 39 39 39 39

L3

42 42 42 42 42 42 42 42 42 42

Article no.

± 0.1

885127 885128 885129 885130 885131 885132 885042 885043 885044 885045 885046 885047 885048 885049 885050 885051 885052 885053 885054 885055 885056 885057 885058 885059 885060 885061 885062 885063 885064 885065 885066 885067 885068 885069 885070 885071 885072

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0

Øds

α°

25-45 25-45 25-45 25-45 25-45 25-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45

Ls = 100 ± 0.1

Ro

Bt

± 0.1

± 0.05

2.8 3.5 4.2 5.0 5.7 6.4 7.2 8.0 8.7 9.5 10.3 11.1 11.9 12.7 12.8 14.4 14.8 16.1 17.0 17.8 18.3 19.6 20.5 21.5 22.4 23.4 24.3 25.3 26.3 27.3 28.3 29.3 30.4 31.4 32.5 33.6 34.7

0.19 0.23 0.28 0.32 0.36 0.41 0.45 0.49 0.53 0.57 0.61 0.65 0.69 0.73 0.73 0.81 0.79 0.88 0.92 0.95 0.93 1.02 1.06 1.09 1.12 1.15 1.19 1.22 1.25 1.28 1.31 1.34 1.36 1.39 1.42 1.45 1.47

L2

L3

Article no.

± 0.1

885133 885134 885135 885136 885137 885138 885081 885082 885083 885084 885085 885086 885087 885088 885089 885090 885091 885092 885093 885094 885095 885096 885097 885098 885099 885100 885101 885102 885103 885104 885105 885106 885107 885108 885109 885110 885111

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0

Øds

α°

25-45 25-45 25-45 25-45 25-45 25-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45 15-45

Ro

Bt

± 0.1

± 0.05

3.2 4.0 4.8 5.0 5.8 7.3 8.2 9.1 10.0 10.8 11.7 12.7 13.6 14.5 15.5 16.4 17.4 18.4 19.4 20.4 21.4 22.4 23.5 24.5 25.6 26.7 27.8 28.9 29.8 31.2 32.4 33.6 34.8 36.0 37.2 38.5 39.2

0.16 0.20 0.24 0.25 0.29 0.35 0.39 0.43 0.46 0.50 0.53 0.57 0.60 0.64 0.67 0.70 0.73 0.77 0.80 0.83 0.86 0.89 0.92 0.95 0.97 1.00 1.03 1.06 1.03 1.11 1.14 1.16 1.19 1.21 1.23 1.26 1.22

L2

L3

CAUTION Bt and Ro dimensions must be complied with! If Ro is calculated smaller or Bt larger than the corresponding form tool diameter, this will lead to overstressing of the form tool holder, pressure cup and riveting spindle guide! +

* = available from stock (α = 15°), = available from stock (α = 25°)

803858.010/ENG

33

Options

7 7.1


Options Pressure pad Use For parts that must be held together before the form tool touches down or parts that need to be pressed together with force for a press fit. Pre-stress force The necessary pre-stress force must be determined through experience or empirically. Pressure pad components (springs, thrust piece) The design of the pressure pad components can be seen in the diagram 802297 (series 081-241) or 802296 (series 270-381). The thrust piece must be made to match the workpiece. The thrust piece influences the pre-stress force, the pretravel with regards to the form tool and the spring rate. In normal cases, the pressure pad is produced specifically for the customer.

NOTICE When using a pressure pad following minimum dimensions for form tool and form tool holder are required: Series 081-241: Form tool length Ls = 54, form tool holder radius Rp = 80 Series 270-381: Form tool length Ls = 84, form tool holder radius Rp = 116

34

803858.010/ENG


7.1.1

Options

Pressure pad dimensions drawing

Machine type 081

151/170/181

220/231

241

270/281

331

381/431

A

max. 30

max. 30

max. 30

max. 30

max. 62

max. 62

max. 62

B

55

55

55

55

90

90

90

C

75

75

75

75

125

125

125

D

7.5 (R80) 27.5 (R100)

7.5 (R80) 27.5 (R100)

7.5 (R80) 27.5 (R100)

7.5 (R80) 27.5 (R100)

4 (R116) 20 (R132) 36 (R148)

4 (R116) 20 (R132) 36 (R148)

4 (R116) 20 (R132) 36 (R148)

E

32

32

32

32

48

48

48

b

Applicationspecific

Applicationspecific

Applicationspecific

Applicationspecific

Applicationspecific

Applicationspecific

Applicationspecific

G

83.5

150.5

170.5

189.5

206.5

247.5

238

Thrust piece production

As per drawing no. 802297 "Production of thrust piece and spring diagram”

803858.010/ENG

As per drawing no. 802296 "Production of thrust piece and spring diagram”

35

Options

7.1.2


Production of thrust piece and spring diagram 802296 Spring diagram

F (daN) spring force

Fmax. 2910 daN

Fmax. 1285 daN

Fmax. 670 daN

f (mm) travel

* Travel f = 0.75h do not exceed if possible

I

6 disk springs 80x41x2.25 (simple)

II

6 disk springs 80x41x3 (simple)

III

5 disk springs 80x41x4 (simple)

36

803858.010/ENG


Options

Example: a and b sought for pre-stress force Fv = 470 daN for I Fv = 380 daN for II Fv = 1250 daN for III Spring combination

Force at 0.75h

I

a = 12 A travel of 7 (until f = 0.75h) remains for b

-> F 660 daN

II

a=8 A travel of 7.4 (until f = 0.75h) remains for b

-> F 1050 daN

III

a = 10 A travel of 4.1 (until f = 0.75h) remains for b

-> F 2250 daN

Thrust piece production

Material thrust piece: Case-hardened steel Ra = 3.2 b = depends on application Case-hardened 0.3...0.5 – 660 ± 20 HV10

803858.010/ENG

37

Options

7.2


Automatic lubrication riveting spindle head The automatic lubrication is recommended mainly for machines and units that are installed in automatic systems and are operated in multi-shifts. It is however also suitable for manual workplaces to ensure regular relubrication of form tool holders and pressure cups. Two machines or units (e.g. RND) can be lubricated simultaneously with a second metering valve. The distance between both machines or units should however not exceed more than 1 meter. A constant air pressure of 6 bar is necessary to operate the device. Setting the grease volume The riveting spindle head is default 3 supplied with approx. 6mm grease. For extremely high loading, this volume can be increased by rotating the level control of the injection lubricator (metering valve) in the "+" direction. One level increases the volume by 3 approx. 1mm .

Monitoring The level monitoring in the grease container is implemented with an initiator whose control state is shown on the control unit display when the grease volume is too low.

Lubrication interval The lubrication interval is specified with the setup parameter in the control unit. The default lubrication interval in the control unit is set to 5h. The default lubrication interval of 5h can be adapted if necessary to the operating requirements. A shorter interval can be set for hard permanent operation in the upper riveting force range or a longer interval for manual insertion operation (see setup table in operating instructions “Control”). Topping up the grease container See Chapter "Maintenance and repair work".

38

803858.010/ENG


7.3

Options

Foot switch If for instance large and/or bulky parts cannot be riveted using a two-hand operating unit, a safety foot switch can be used.

7.3.1

Function When the safety foot switch is actuated, the make contact is closed and the riveting procedure initiated. When the pedal is released, the riveting spindle automatically returns to the start position.

CAUTION Foot switch is activated unintentionally! Contusions, scrapes! Set the riveting machine to the smallest possible stroke for the processing. 7.3.2

Dimensions drawing

803858.010/ENG

39

Options

7.3.3


Technical specifications Type F1-U1Z UN

Type F1-U2ZD UN

606.1600.006

606.1700.008

Additional safety pressure point to interrupt the operating process

No

Yes

Creep switching element

Yes

Yes

Jump switching element

No

No

Voltage

500 VAC

500 VAC

Permanent current

10A

10A

Start-up current as per IEC 947-5-1 AC 15/DC 13

Yes

Yes

Switching frequency max.

50/min.

Part number

Wiring diagram

40

6

50/min.

10 x 10

Ambient temperature, min..max.

-30°C/+80°C -22°F/+176°F

-30°C/+80°C -22°F/+176°F

Approvals

CSA, UL

CSA, UL, BG

Cable entry

1 x M20 x 1.5

3 x M20 x 1.5

Weight

1.5kg / 3.3lb

1.6kg / 3.5lb

803858.010/ENG

10 x 10

6

Mech. service life - number of cycles


7.4

Options

Initiator upper end position The upper end position of the riveting spindle is monitored by an initiator and can send the control unit the required pulse for an upstream or downstream machine (e.g. rotary indexing table, pneumatic sliding table, etc.). For further information, such as settings and connection diagrams, refer to the operating instructions of the control unit without path-measuring system HPP

7.5

with path-measuring system HPP

Initiator lower end position (bridging initiator) The lower end position initiator is used for self-holding the two-hand operating unit. For further information, such as settings and connection diagrams, refer to the operating instructions of the control unit.

803858.010/ENG

41

Maintenance and repair work

8



8.1

Introduction The maintenance and repair work on the machine comprises periodic cleaning, lubrication, inspection and upkeep work. All completed maintenance and repair work must be entered in the maintenance and repair log by the persons responsible for the work (example form see chapter “Maintenance and repair log“).

8.1.1

Safety regulations If, during maintenance, it is noted that a machine part is defective or damaged, it must be correctly repaired or replaced. Only use original spare and wear parts. Inform operating personnel before starting any maintenance and repair work. Implement specified adjustment, maintenance and inspection work according to the schedule.

8.1.2

Personnel requirements For safety reasons, maintenance and repair work may only be carried out by trained specialist personnel.

42

803858.010/ENG


Overview of maintenance work

X

Riveting spindle

X

X X X

X

Automatic lubrication riveting spindle head (option)

X

Hydraulic aggregate

X X

When the corresponding indication appears on the control unit display X

Filter Hydraulic aggregat

X

X

Polygon shaft

X X

X

Two-hand operating unit

X

X

Piston and piston rod seals Riveting motor terminal box

X

X

803858.010/ENG

Each time riveting unit is dismantled

X X

Every 5000h or 2 years

Riveting spindle head (form tool holder and pressure cup)

Every 1000h or annually

Maintenance interval (whichever is reached first)

Type of maintenance

Every 40h or weekly

Assembly

Check Relubrication Removal Cleaning New lubrication Topping up Emptying Replacement

8.2


X

X

43


8.2.1


Riveting spindle head (form tool holder and pressure cup)

7 Item

Name

1

Form tool holder spherical plain bearing

2

Pressure cup

3

Form tool holder

4

Lubricator nipple

5

Red cap

6

Screwed connection for automatic lubrication

7

Grease gun (Article No. 459806)

Riveting spindle head (form tool holder and pressure cup) maintenance schedule Name

Pressure cup/form tool holder

Maintenance activity

44

Interval Every 40 h or weekly. Lubrication intervals should be reduced for extremely high stresses (temperature at red cap over 40° C) or during shift operation.

Lubricate with one shot of the grease gun via the lubricator nipple

Clean, check for wear, relubricate Form tool holder spherical plain bearing

Grease type

Klübersynth GE 46-1200

Clean and check for wear, relubricate, replace if necessary

803858.010/ENG

Every 1000 h or after every replacement of pressure cup/form tool holder Every 1000 h or after every replacement of pressure cup/form tool holder


8.2.2


Riveting spindle

803858.010/ENG

45



Riveting spindle maintenance schedule

8 9 10 25 37 38 39 40 44 46 47 48

Eccentric sleeve Eccentric shaft Internal ring gear Needle ring Axial ball bearing Needle bearing Needle ring Washer Lip seal O.D. seal Lip seal O-Ring

X X X

X X X X X X X X X X X

49

Compensating washer

X

50 52 53 54 55 56

O-Ring Thrust disk Thrust disk Compensating washer Axial needle ring Casing washer

X X X X X X

Mobil DTE 24

Lubricate

Replacement

Name

Dismantle

Clean and check for wear, replace if necessary

Item

Klüber-Staburags NBU 8 EP

Grease type

Maintenance activity

Comments

X X X X X X X X X X Item 49 must be centered on the upper piston item 4 during assembly (grease item 49 with Klüber-Staburags NBU 8 EP to make it easier)

X

X

X X

The riveting unit must be completed disassembled every 2 years or 5000 operating hours for maintenance lubrication. All parts must be cleaned and the bearing surfaces must be checked for wear or burnt areas. The needle rings and axial needle bearings of the eccentric shaft must be replaced (see maintenance list). All parts must be carefully reassembled after being newly lubricated.

NOTICE This revision interval should be shorted appropriately if high stresses are involved (higher material stressing)!

46

803858.010/ENG


8.2.3


Automatic lubrication riveting spindle head (option)

Item

Name

Item

Name

1 2 3 4 5 6

Injection lubricator (metering valve) Lubricant line Solenoid valve Screwed connection Plug screw 3 Grease container (27.6 cm )

7 8 9 10 11

Initiator Container cover Pistons Pressure control valve Compressed air hose

Topping up the grease container

ATTENTION Container is under pressure! Grease squirts out of container! To topping up stop the compressed air supply! The grease level in the grease container can be determined from the position of the piston. When the end protrudes less than 4 mm out of the container cover or when a corresponding indication appears on the control unit display, the grease container must be topped up as follows: 1. Stop compressed air supply to riveting machine 2. Disconnect compressed air hose at connection 3. Remove the lubricant line and the aperture plug screw on the grease container 4. Push the piston through the aperture down to the stop. Slowly top up with grease (Klübersynth GE 46-1200) until it starts to come back out of the same aperture. 5. The grease must leak through the screw connection when the plug screw is mounted again. 6. Reconnect the lubricant line. Manually actuate the injection lubricator several times --> there must not be any air in the lubricant line!

803858.010/ENG

47


8.2.4


Hydraulic aggregate Filter The hydraulic aggregate is furnished with a filter. Filtration: 10 Microns The filter must be checked at least once a year or after 1000 operating hours. If necessary the aerating filter needs to be cleaned and the filter cartridge needs to be replaced. Hydraulic oil Under normal use, the hydraulic oil should be replaced approximately every 2 years or after 5'000 operating hours. At the same time, the aerating filter needs to be cleaned and the filter cartridge needs to be replaced.

CAUTION Leakage of hot hydraulic oil! Light burns! Drain hoses before a maintenance!

Recommended oils Temperature range Type

+10 up to +55ºC

+20 up to +65ºC

Quality 2

48

2

ISO-VG 32 (32 mm /s) at 40ºC

ISO-VG 46 (46 mm /s) at 40ºC

BP

BP Energol HLP 32, BP Energol HLP-D 32

BP Energol HLP 46, BP Energol HLP-D 46

ESSO

NUTO H 32

NUTO H 46

MOBIL

Mobil D.T.E. 24

Mobil D.T.E. 25

SHELL

SHELL Tellus Oil 32

SHELL Tellus Oil 46

CASTROL

CASTROL HYSPIN AWS 32

CASTROL HYSPIN AWS 46

803858.010/ENG



Filling of hydraulic oil 

Remove plugs from the elbow connection pieces of the valve manifold.



Fill the oil tank with the specified oil via the oil filler until the oil level reaches the upper mark on the oil level indicator.

NOTICE Fill the oil tank with filtered hydraulic oil only! Ensure that there is no hydraulic oil spilled during the filling (hydraulic oil may not spill into the environment)!

Oil tank capacity Series 241 (without rapid speed/working speed)

Series 381 Series 431

Series 481 Series 241 (with rapid speed/working speed)

ca. 15 L

ca. 24 L

ca. 61 L

Hydraulic hose lines The hydraulic hose lines have to be checked regularly for leak tightness or damage and replaced if necessary! Motor terminal box The motor terminal box of hydraulic aggregate has to be always closed during the operation. The terminal box can be opened for maintenance or fault finding.

DANGER Touching of live parts on the open terminal box! Electric shock! Isolate the electrical power supply! Electrical commissioning has to be made only by a trained authorised electrician!

803858.010/ENG

49


8.2.5


Polygon shaft

It is strongly recommended, for preventative maintenance regarding machines subject to high stresses and multiple shift work, that the polygon profile is cleaned every 1000 operating hours or at least annually and lubricated again with Interflon Grease LS1/2.

NOTICE This point applies in particular to riveting machines that are equipped with the Process-Controller.

50

803858.010/ENG


8.2.6


Two-hand operating unit The two-hand operating unit must be checked regularly, at least once a year, by an expert provided by the operator. This check must cover: 1. The secure function of the two-hand operating unit 2. The condition of the two-hand operating unit components 3. The interaction of the two-hand operating unit with the riveting machine control unit The test results must be documented in a report to be signed by the tester. The report must be retained. Safety inspection After every change in working procedures, e.g tool change, change to activation type "Two-hand operating unit", additions of further safety equipment, the following must be checked: 1. That the two-hand operating unit required for safety is switched on and functional 2. That the two-hand operating unit and exposed connection lines are visually undamaged 3. That the necessary safety distance is complied with

Check list for two-hand operating unit check Does the riveting machine start after actuation of the two-hand button at an interval of < 0.5 sec.?

8.2.7

Yes

No

X

Does the riveting machine start after actuation of the two-hand button at an interval of > 0.5 sec.?

X

Two-hand button and exposed lines damaged?

X

Safety distance complied with?

X

Is the start lifting movement interrupted if one button is released?

X

Piston and piston rod seals

NOTICE The piston and piston rod seals must always be replaced when the riveting machine is disassembled (seals may be damaged during inappropriate removal of riveting unit). Seals must be carefully reassembled after being newly lubricated (see riveting spindle maintenance schedule).

803858.010/ENG

51


8.2.8


Riveting motor terminal box The riveting motor terminal box can be opened for maintenance or fault finding.

DANGER Touching of live parts on the open terminal box! Electric shock! Isolate the electrical power supply! Electrical commissioning has to be made only by a trained authorised electrician!

52

803858.010/ENG


8.3


Maintenance and repair log All maintenance and repair work carried out by the customer or BalTec must be entered into a maintenance and repair log. Copy the maintenance and repair log shown in these operating instructions and enter the following data: 

Effective operating hours (shown on the control unit display)



Tick in cycle column



Work carried out

 Name and date Archive the completed forms. Example form Maintenance log for Machine : RN 231

Machine no.: 231.9999

00050

Every 2 years or 5000 operating hours

Yearly or every 1000 operating hours

Half-yearly or every 500 operating hours

Weekly or every 40 operating hours

Riveting unit dismantled

Counter display: Operating hours

Work carried out

X

Work

Carried out by

Date

Lubricate riveting spindle head

S.Template

22.05.05

01025

X

Polygon shaft cleaned and lubricated

S.Template

24.06.05

01025

X

Two-hand switching checked

S.Template

24.06.05

Riveting machine checked

S.Template

24.10.05

05060

X

X

803858.010/ENG

53

54 Every 2 years or 5000 operating hours

Maintenance log for Machine:

Yearly or every 1000 operating hours

Half-yearly or every 500 operating hours

Weekly or every 40 operating hours

Riveting unit dismantled

Counter display: Operating hours

Maintenance and repair work Radial riveting machine RNE 381

Maintenance and repair log

Machine no.: Work carried out

Work

803858.010/ENG

Carried out by Date


9 9.1

Decommissioning, Storage

Decommissioning, Storage Decommissioning Disconnect the riveting machine from power and pressure before shutting it down and dismantling it.

9.2

Storage Please note the application limitations for storage.

9.3

Re-commissioning Before recommissioning or after a long standstill, the pressure cup in the riveting spindle head must be lubricated first (see Chapter "Maintenance and repair work"). For the remaining procedures, follow the instructions in the Chapter "Commissioning" or Assembly instructions.

803858.010/ENG

55

Disposal


10 Disposal 10.1 Introduction 10.1.1 Personnel requirements For safety reasons, disposal must be carried out only by trained specialist personnel. 10.2 Disposal 10.2.1 Replaced parts Disposal of replaced parts such as seals, filter cartridges and hydraulic oils and lubricants in particular is determined by the local disposal regularions and the environmental protection laws. 10.2.2 Mineral oils The mineral oils recommended by us can be recycled depending on the level of contamination and decomposition. See also the manufacturer specifications. 10.2.3 Riveting unit Once the machine has reached the end of its service life, dismantling must include safe and correct disposal of all parts, in particular those materials or parts that could be a hazard to the environment. These include:

56



Lubricants



Hydraulic oils



Plastics



Batteries



Pressure accumulator (depressurize, empty)

803858.010/ENG


Appendix

11 Appendix 11.1 Schemata 11.1.1 Hydraulic diagram 381 801949-d GRIBI diagram no. A1212-2049

Pos.

Name

Pos.

Name

1

Geared pump

9

Tank cover

2

Connecting flange

10


3

Connecting flange

11

Valve manifold

4

Intermediate flange

12

Glycerine manometer

5

Coupling

13

Pressure limit cartridge

6

Electric motor

14

4/3-port directional control valve

7

Oil tank

15

Non-return valve sandwich

8

Oil level indicator

16

Non-return valve

803858.010/ENG

57

Appendix


11.1.2 Pneumatic diagram for automatic lubrication 802417

58

Item

Name

0.1

Pressure control valve

1.0

Grease container

1.1

Solenoid valve

2.0

Injection lubricator (metering valve)

803858.010/ENG


Appendix

11.2 Spare parts lists 11.2.1 Machine body 381 Standard/HPP 852401-b

803858.010/ENG

59

Appendix

60


803858.010/ENG


Appendix

803858.010/ENG

61

Appendix


Pos.

No.

Part name

Part no.

1

1

Cast housing

852093

2

1

Motor flange

852095

Standard

3

1

Flange below

852005

Standard

4

1

Upper piston

852094

5

1

Lower piston

852008

6

1

Cam

852054

7

1

Key

390108

8

1

Eccentric sleeve

852002

9

1

Eccentric shaft

838014

10

1

Internal ring gear

842053

11

1

Connection piece

853007

12

1

Key

842016

13

1

Scale

842014

14

1

Adjustment ring

852030

15

1

Motor flange

852096

HPP

16

1

Cover tube

852040

Standard

17

1

Washer

852000

18

1

Flange below

852063

for flange mounting

19

1

Cover tube

852064

for flange mounting

20

1

Distance tube

835250

21

1

Adhesive label "BalTec"

825110

24

1

Fixing nut

522545

E-8, M10x1

25

1

Needle ring

331049

K 20x28x25

26

8

Screw

341928

In-6kt low head M10x20 DIN 7984-8.8

27

8

Screw

341040

In-6kt M10x30 DIN 912-12.9

28

8

Locking washer

351710

for M10

29

3

Screw

342806

M4x10

30

2

Screw

341009

In-6kt M4x8 DIN 912-12.9

31

3

Screw

341916


32

4

Screw

341520

In-6kt M6x35 DIN 912-12.9

33

1

Locking screw

838094

34

1

Dowel pin

356108

ø4x16 VSM 12785

36

4

Screw

341911


62

803858.010/ENG

Remarks


Appendix

Pos.

No.

Part name

Part no.

Remarks

37

2

Axial ball bearing

330059

51109

38

2

Needle bearing

331267

NK 45/20

39

1

Needle ring

331048

K 20x24x17

40

1

Washer

330704

LS 2035

43

1

Stop nut

348993

Nyloc M8

44

1

Lip seal

362778

HALLITE Type 616, LI Ø45x56x3,9mm

45

1

Proximity switch

522665

M8x1 PNP/NO BES 516-324-SA33

46

1

O.D. seal

362431

NTH – Ring K 100238

47

1

Lip seal

362779

HALLITE Type 616, LI Ø75x90.5x6mm

48

2

O-Ring

362121

94 – 3 NBR 70 Shore

49

1

Compensating washer

337006

L&M 51/61x0.5

50

1

O-Ring

362082

59.5 – 3 NBR 70 Shore

52

1

Thrust disk

842189

53

1

Thrust disk

842190

54

1

Compensating washer

337007

L&M 28/34.5x0.5

55

2

Axial needle ring

330005

AXK 2035

56

2

Casing washer

330182

GS 81104 (ø20/35)

57

2

Cable clamp

525305

58

2

Screw

346748

M3x8 DIN 7500 C

59

1

Proximity switch

522517

M5 PNP/NO

60

1

Proximity switch holder

824053

62

2

Stopper

371513

TL-4-193

63

1

Stopper

371507

TL-4-093 for M10x1

65

1

Clamping fixture complete

853050

70

1

Angle connector with cable

522532

1

Set of bearings

333412

1

Set of seals

363566

803858.010/ENG

BKS-S 49-1-03

63

Appendix

Pos.

No.


Part name

Part no.

Remarks

RNE without pressure monitoring 85

2

Pipe fitting straight

366085

GE 15-PLR-ED

RN without pressure monitoring 85

2


366085

GE 15-PLR-ED

91

2

Tube

842092

92

2

Union nut

374917

M 15-L

93

2

Cutting ring

367815

DPR 15-L

RN/RNE/RNS with pressure monitoring 80

2

Adjustable angle connection piece

367514

EVL 15 PL

81

2

Reducing fitting

367812

KOR 5/10 PL

82

2

Tube

852050

83

2

Adjustable threaded elbow joint

374417

EVW 10 PL

84

2

Manometer fitting

369854

MAVE 10 LR

85

2


366085

GE 15-PLR-ED

90

1

Pressure transmitters fixing

852070

RNS without pressure monitoring 85

2


366085

GE 15-PLR-ED

94

2

Angle connection piece

374419

EVW 15-PL

RND without pressure monitoring 95

1

Swivelling fitting

366910

WH15LRKDSCF

96

1

Elbow connection piece

367541

EW15LREDCF

64

803858.010/ENG


Appendix

11.2.2 Riveting head 270-431 838310-k

Pos.

No.

Part Name

Part No.

Remarks

1

1

Cap

838004

RN/RNE 281-431 Standard/HPP RNL/RNEL 281-331 Standard

5

4

Screw

341011

In-6kt M4x12 DIN 912-12.9

6

1

Pressure spring

840139

to form tool holder R = 100-148

7

2

O-Ring

362129

100-2

803858.010/ENG

65

Appendix


Pos.

No.

Part Name

Part No.

Remarks

8

1

Form tool holder complete

838050

R = 100 / L = 68

9

1


838051

R = 116 / L = 84

10

1


838052

R = 132 / L = 100

11

1


838053

R = 148 / L = 116

12

1

Pressure cup

838058

R = 100 / L = 68

13

1

Pressure cup

838059

R = 116 / L = 84

14

1

Pressure cup

838060

R = 132 / L = 100

15

1

Pressure cup

838061

R = 148 / L = 116

16

1

Lubricating nipple

319718

17

1

Ring fitting

366916

18

1

Hollow core screw

374179

H1 M5 K

19

2

Bonded seal

361108

USIT 5.7x9x1

20

1


838083

R = 170 / L = 138

21

1

Pressure cup

838084

R = 170 / L = 138

22

1


838085

R = 191 / L = 159

23

1

Pressure cup

838062

R = 191 / L = 159

24

1


838087

R = 240 / L = 208

25

1

Pressure cup

838086

R = 240 / L = 208

26

1

Pressure spring

836028

to form tool holder R = >148

27

1

Cap

838176

RNL/RNEL 281-331 HPP

28

1

Cap

865855

RN/RNE 281-431 NHE RNL/RNEL 281-331 NHE

29

1

Cap

846006

RNL/RNEL 381 Standard/HPP/NHE

30

1

Block

814151

31

2

Screw

341024

In-6kt M6x16 DIN 912-12.9

32

1

Oil hose

040034

PA Ø2.5/1.5 L = ca. 500mm

33

2

Connection fitting

366913

35

1

Cap (reworked)

868724

RN/RNE 281-431 with NHE hold-down force 236N

101

1

Spherical plain bearing to form tool holder

325805

GE 15 DO

102

1

Circlip to form tool holder

354517

SB26

103

3

Spring-loaded thrust pad to form tool holder

349891

GN 615-M4-K

1

Swivelling screw-fitting to lubricator „perma STAR CONTROL“

366151

M5x0.8d D=6

66

803858.010/ENG


Appendix

11.2.3 Electric motor 381 852320-k

Pos.

No.

Part name

Part no.

Remarks

1

1

Spring dowel sleeve

355401

PRYM ø5x35 ISO 8748

2

1

Feed cable motor

520169

3

1

Electric motor

542854

4

1

Polygon shaft

852055

5

4

Cylinder head screw

341530

In-6kt M8x35 DIN 912-12.9

6

1

Electric motor

542855

3x575V 60Hz

7

1

Electric motor

8

1

Polygon shaft

852056

USA

12

1

Cable fitting

525794

M20x1.5 5.5-12.0mm

14

1

Cover

842213

15

1

Electric motor

542908

3x200V 50Hz

17

3

Pan head screw

359137

M4x8 eco-fix H BN 4825 4H

18

1

Cover bracket

853080

22

1

Feed cable motor

520169.01 USA/Canada

3x230/400/415V 50Hz 3x230/460V 60Hz

USA

803858.010/ENG

67

Appendix


11.2.4 Automatic lubrication 814340-u

68

803858.010/ENG


Appendix

Pos.

No.

Part name

Part no.

Remarks

1

1

Grease container

814112

2

1

Pressure regulating unit

368325

DR.022-L378

12

1

Plug socket

369347

black 22mm 230-364 A

14

1

Injection lubricator

378008

L11 R 1/8“ KY 2033

Single parts to Pos. 14 obtainable: 14.1

1

Clamping ring

366912

2.5x1.5 brass

14.2

1

Tube connection

366911

M8x1.00x3/32“

15

1

Connection fitting

366913

Single parts to Pos. 15 obtainable: 15.1

1

Clamping ring

366912

2.5x1.5 brass

18

1

Swivelling fitting

366150

1/8“, D=4 Art.-Nr. 0118 04 10

19

3

Screw plug

371012

B 18 23-02

21

1

Swivelling fitting

367744

1/8" 834-0204 K

23

1

Swivelling fitting

367746

1/4" 834-0404 K

25

1

Plastic hose

040026

PS 64

26

1

Plastic hose

040037

PA ø4/2.7

27

1

Oil hose

040034

PA ø2.5/1.5

28

2

Cylinder head screw

341015

In-6kt M5x8

29

1

Cylinder head screw

341027

In-6kt M6x30

30

1

Cylinder head screw

341026

In-6kt M6x25

31

1

Feeding cable valve

520235

33

1

Proximity switch

522520

M5 PNP NC BES 516-3022-E5-C-S49

34

1

Angular plug connector with cable

522532

BKS-S 49-1-03

35

1

Locking plug

371531

PE 4.5 mm

38

1

Filter

368337

¼“ F.01

39

1

Bracket assembly set

368353

40

4

Cylinder head screw

341017

In-6kt M5x12 DIN 912-12.9

Lubricating grease (1kg can)

060309

Klübersynth GE 46-1200

803858.010/ENG

69

Appendix


11.2.5 Foot switch 813345-d

Pos.

No.

Part name

Part no.

Remarks

1

1

Foot switch

522427

F1-U1 UN

2

1

Reduction flange

525894

only for Canada

3

1

Cable fitting

525719

Pg11/6-12mm, only for Canada

4

1

Cable configured

520146

2x1.5E length = 2.5m, only for Canada

5

1

Cable fitting

525794

M20x1.5/5.5-12mm

6

1

Cable configured

520145

2x1 length = 2.5m

7

1

Case with switch

522621

F1-U1 UN

8

1

Spring

522426

F1-U1 UN

9

1

Foot switch

522429

F1-U2ZD UN

10

1

Case with switch

522430

F1-U2ZD UN

11

1

Ram incl. spring

522431

F1-U2ZD UN

12

1

Cable configured

520623

4x1.5E length = 2.5m

13

1

Cable configured

520622

4x1 length = 2.5m

70

803858.010/ENG


Appendix

11.2.6 Two-hand operating unit 814350-d

Pos.

No.

Part name

Part no.

1

1

Housing

814109

2

1

Cover

814107

without emergency stop

3

1

Cover

814108

with emergency stop

4

2

Cylinder screw

341016

In-6kt M5x10 DIN 912-12.9

5

2

Press button

522297

green

6

1

Cable fitting

525772

Pg 11, 5-12mm

7

1

Counter nut

525204

Pg 11

8

1

Cable clamp

525304

9

1

Cylinder screw

341009

In-6kt M4x8 DIN 912-12.9

10

1

Cylinder screw

341015

In-6kt M5x8 DIN 912-12.9

11

1

Press button

522296

red, emergency stop

12

1

Supply cable

520233

RC-20, L=2000

13

1

Supply cable

520232

RC-20, L=1400

14

1

Supply cable

520660

RC-30/HPP-25, L=1500

15

6

Pan head screw

346090

M3x6 ECO-FIX Form H, BN 4825 4.8

16

1

Supply cable

520661

RC-30/HPP-25, L=2000

803858.010/ENG

Remarks

71

Appendix


11.2.7 Pressure pad 270-431 838315-g

72

803858.010/ENG


Appendix

Pos.

No.

Part Name

Part No.

Remarks

1

1

Pressure piece

2

1

Cap

838016

3

1

Pressure spring

840139

4

4

Cylinder head screw

341507

In-6kt M4x30 DIN 912-12.9

5

2

O-Ring

362129

100-2

6

1

Straight pin

355069

ø3h6x12 DIN 6325

7

1

Snap ring

354264

In 82x2.5 DIN 472

8

1


838051

R = 116 / L = 84

9

1


838052

R = 132 / L = 100

10

1


838053

R = 148 / L = 116

11

1

Pressure cup

838059

R = 116 / L = 84

12

1

Pressure cup

838060

R = 132 / L = 100

13

1

Pressure cup

838061

R = 148 / L = 116

14

6

Spring washer

314252

80x41x2.25 (60 – 660 daN)

15

6

Spring washer

314253

80x41x3 (100 – 1050 daN)

16

5

Spring washer

314254

80x41x4 (100 – 2250 daN)

17

1

Pressure spring

836028

Form tool holder >R = 148

18

1

Lubricating nipple

319718

19

1

Banjo fitting

366916

20

1

Hollow-core screw

374179

H1 M5 K

21

2

Bonded seal

361108

USIT U 5.7-9-1

22

1


838083

R = 170 / L = 138

23

1

Pressure cup

838084

R = 170 / L = 138

24

1


838085

R = 191 / L = 159

25

1

Pressure cup

838062

R = 191 / L = 159

26

1


838087

R = 240 / L = 208

27

1

Pressure cup

838086

R = 240 / L = 208

28

1

Cap

838189

RNL/RNEL 281-331 HPP

29

1

Aluminium sealing ring

363681

DA M5

30

1

Block

814151

31

2

Cylinder head screw

341024

In-6kt M6x16 DIN 912-12.9

33

1

Oil hose

040034

PA Ø2.5/1.5 L= ca. 500mm

34

1

Connection fitting

366913

client specific

803858.010/ENG

RN/RNE 281-431

73

Appendix


11.2.8 Hydraulic aggregate RNE 381 852435-q

Pos.

No.

Part name

Part. No.

Remarks

3

2

Straight connection piece

366124

G15LCFX

4

2

Feed cable to valve

520234

L=1500mm

5

1

Feed cable to motor

520169

6

1

Feed cable to motor

520169.01 USA/Canada

10

1

Star knob

390059

11

2

Hydraulic hose

388066

L=2000mm

14

1

Hydraulic aggregate complete

374925

3x220-420V,50Hz

16

1


374919

3x575V, 60Hz

18

1


374920

3x200V, 50Hz

35

2

Screw plug

371426

G 1/8“

41

1

Geared pump

381022

WSP10.6,3D0-81E1-LBB/BA-N

42

1

Connecting flange

374951

RBA30/18-M

74

803858.010/ENG


Appendix

Pos.

No.

Part name

Part. No.

Remarks

43

1

Connecting flange

374952

RBA30/10-M

44

1

Intermediate flange with centering disc

374886

LMC200MFS1004E

45

1

Elastic coupling

325211

G-124/1P

46

1

Electric motor

542935

1.1/1.27kW 3x220-240V/380-420V

47

1

Electric motor

542931

1.1/1.3kW 3x575V

48

1

Electric motor

542932

1.1/1.3kW 3x200V

49

1

Oil level indicator

378215

FSA-127-1.1/T/12

50

1


379733

HF554-10129-AS-FG010-B17-GD-B-S-Z

51

1

Glycerine manometer

369806

Ø63 0 – 160bar 1/4B

52

1


374946

DVP-2-10-SL max.70bar

54

2

Hydraulic hose

388067

L=2200mm

55

2


366041

GE 15-L/3/8"

56

1

Casing

852031

57

1

Tube

852032

58

1

Valve block

852122

59

1


368108

60

1

Glycerine manometer

369809

61

1

Manometer screwed joint

369852

MAV 6-LR

62

2


366056

GE06LR1/4EDOMDCF

63

2


366082

GE 6-PLR-ED

64

1

Swivelling screw-fitting

366921

SWVE 6-PLR

65

1

T-Connection piece

367572

EVT 6-PL

66

1

Sealing cone

371441

BUZ 6-L

67

2

Socket screw

341516

In-6kt with shank M5x50

68

4

Socket screw

341071

In-6kt M5x25

69

2

Plug socket transparent

369349

Type A

70

1

Filter cartridge to return line filter

379734

HEK05-10.129-AS-FG010-VM-B17-B

73

1

4/3-port directional control valve with 369512 plug

WEDO-43-J-6-V-1/24V DC-N

74

1

Non-return valve sandwich

369002

SRV.AA-6-S97, with nozzle 0.8

75

1

Non-return valve

369001

RV 3/8“

803858.010/ENG

NG4, DDPC-1L-4-10-H-1

75

Appendix


11.2.9 Pressure transmitters fixing 852070-e

Pos.

No.

Part Name

Part No.

1

1

Distributor

852071

2

2

Pressure transmitter

540394

RNE 381, 0 - 100 bar

3

2

Hydraulic hose

387716

L = 1.3m

4

4

Straight screw fitting

366090

GE 6 PSR ED G 1/4“

5

2

Straight screw fitting

366082

GE 6 PLR ED G 1/8“

6

2

Sealing cone

371441

BUZ 6-L

7

2

Cylinder head screw

341520

In-6kt M6x35

8

2

Pressure transmitter

540394

RNE 481, 0 - 200 bar

9

2

Connection cable to pressure transmitter

540393

L = 2m

76

803858.010/ENG

Remarks


Appendix

Manufacturer Baltec Maschinenbau AG Obermattstrasse 65 CH-8330 Pfäffikon ZH Schweiz

Tel.: 0041 (0)44 953 13 33 Fax: 0041 (0)44 953 13 44 [email protected] www.baltec.com

Representative list Ägypten UTP Group Ltd. 5, lbn El Nabih Street Zamalek, Cairo Egypt

Frankreich Tel.: 0020 2 736 05 34 Fax: 0020 2 736 33 53 [email protected]

Australien Bliss & Reels Co. Pty. Ltd. 9 Kim Close P.O. Box 215 Bulleen, Victoria 3105 Australia

Tel.: 00372 780 35 37 Fax: 00372 780 35 39 [email protected]

BeNeLux Heesen-ICA B.V. Afrikalaan 14 A NL-5232 BD's-Hertogenbosch Nederland

Tel.: 0031 73 641 7365 Fax: 0031 73 642 5735 [email protected] www.heesen-ica.nl

Brasilien BalTec do Brasil Av. Marginal Direita da Anhanguera, 480 Jundiaí 13214-658 SP Brasil

Dänemark Sneholt & Nilsen A/S Adalen 9 DK-4600 Koge Denmark

Singapur

Francis Klein & Co. Private Ltd. Tel.: 0091 80 2227 2781 70/1, Mission Road 0091 80 2227 2782 IN-Bangalore - 560 027 Fax: 0091 80 2227 6324 India [email protected]

NLC Singapore Pte. Ltd 50 Bukit Batok St 23 # 04 – 11 Midview Buildings Singapore 659 578

Italien

Slowakei

Camar S.p.A. Via Genova, 58/A IT-10090 Cascine Vica – Rivoli (TO) Italia

Tel.: 0039 011 959 1626 0039 011 959 2970 Fax: 0039 011 959 4101 [email protected] www.camarspa.it

OK Strojservis, s.r.o. Bancìkovej 1/A SK – 821 03 SVK-Bratislava Slevensko

Tel.: 0081 6 6901 1875 Fax: 0081 6 6905 8241 [email protected] www.nakaseiki.co.jp

INTERMER d.o.o. Peruzzijeva ulica 127g Sl-1000 Ljubljana Slovenija

Tel.: 0057 1 413 7755 Fax: 0057 1 413 7755 [email protected] www.imocom.com.co

Dongso P.A. International 3F Dongso-Bldg. #181 Baekjegoboon-Ro, Songpa-Gu, Seoul, Korea Jamsil-Dong, 138-864

Tel.: 0082 2 338 0770 Fax: 0082 2 338 8496 Mobile: 0082 10 5663 0770 [email protected] [email protected]

Tel.: 00351 232 848 042 Fax: 00351 232 848 050 [email protected]

Südafrika

Colly Components AS Rasebotgsgatan 9 SE-16406 Kista Schweden

Tel.: 0046 8 703 02 57 Fax: 0046 8 703 98 41 Mobile: 0046 70 520 25 05 [email protected]

Rothco (Pty.) Ltd. P.O. Box 1756 6 Derrick Road, Spartan Kempton Park Johannesburg South Africa

Thailand Krasstec Company Ltd. 1205 Rama9 Soi55 Rama 9 Rd Suan Luang, Suan Luang THA-Bangkok 10250 Thailand

Tel.: 0043 6246 72788 Mobile: 0043 664 3420959 Fax: 0043 6246 72980 [email protected] www.hamotek.at

Deutschland PLZ: 0, 1, 39, 95-99

Polen

Tschechien

KLEINIG engineering Dechwitzer Str. 16 Gewerbepark Störmthal DE-04463 Großpösna b.Leipzig Deutschland

OK-Strojservis Polska Sp. z o.o Tel.: 0048 690 368 321 ul. Technologiczna 2A [email protected] PL-45-839 Opole www.ok-strojservis.pl Polska

OK Strojservis, s.r.o. Na Kasárnách 152 CZ-396 01 Humpolec Czechia

Deutschland PLZ: 2, 3 (ausser 39), 4, 5

Rumänien

Türkei

Technisches Büro Diehl GmbH Industriestrasse 80a DE-40764 Langenfeld Deutschland

ALFLETH ENGINEERING AG N. Titulescu Str. 2 RO-500010 Brasov România

OY C.Lindholm Engineering Ab. Trollbergintie 10 FI-10650 Tammisaari Finnland

[email protected] [email protected] Tel.: 0040 268 510 012 Fax: 0040 268 510 011

Russland Tel.: 00358 207 519 600 Fax: 00358 207 519 619 [email protected] www.clegroup.eu

Tel.: 00386 1 280 86 83 Mobile: 00386 41 676 583 Mobile: 00386 41 793 073 Fax: 00386 1 280 86 89 [email protected]

Socio de servicio técnico: Tojaltec-Fabrico de Máquinas Zona Industrial de Vilar de Besteiros Lote 2 PT-3465-190 Tondela Portugal

HAMOTEK Montagetechnik GmbH Untersbergstrasse 1b AT-5082 Grödig Oesterreich

Finnland

[email protected] Tel.: 0042 0563 034 505 Fax: 0042 0257 181 056

Tel.: 0034 630 442 457 [email protected]

Oesterreich, Deutschland PLZ: 83

Tel.: 0049 2173 963 07 06 Fax: 0049 2173 963 07 08 [email protected] [email protected] www.tb-diehl.de

Tel.: 0065 6268 5911 Fax: 0065 6268 2170 Mobile: 0065 9830 3017 [email protected]

BalTec Espanã Avda Guadalix 26 bis ES-28702 Ciudalcampo S. Sebastian de los Reyes (Madrid) Espanã

BalTec Maschinenbau AG Home-Office Am Bahndamm 18/1 DE-73342 Bad Ditzenbach Deutschland

Tel.: 0049 34297 14 36 0 Mobile: 0049 171 673 10 70 Fax: 0049 34297 14 36 27 [email protected]

Tel.: 0041 (0)44 953 13 33 Fax: 0041 (0)44 953 13 44 [email protected] www.baltec.com

Spanien, Portugal

Imocom S.A. Calle 17 No. 50-24 111611 Bogotá Colombia

Deutschland PLZ: 6, 7, 8 (ausser 83), 90-94 Tel: 0049 7335 923 412 Fax: 0049 7335 923 3069 Mobile: 0049 175 1816 132 [email protected]

Tel.: 0046 8 703 02 57 Fax: 0046 8 703 98 41 Mobile: 0046 70 520 25 05 [email protected]

Slowenien, Kroatien

Naka Seiki Co. Ltd 2-17, 1-Chome, Kinda-cho Moriguchi, JP-Osaka 570-0011 Japan

Norwegen Tel.: 0045 4615 4600 Fax: 0045 4615 4225 [email protected] www.sneholt-nilsen.dk

Baltec Maschinenbau AG Obermattstrasse 65 CH-8330 Pfäffikon ZH Schweiz

Indien

Korea Tel.: 0086 21 6430 0732 Fax: 0086 21 6430 1653 [email protected] [email protected] www.baltec.cn

Colly Company AB Rasebotgsgatan 9 SE-16406 Kista Schweden

Schweiz Tel.: 0044 1189 311 191 Fax: 0044 1189 311 103 [email protected] [email protected] www.baltecuk.com

Kolumbien Tel.: 0041 (062) 888 70 00 Fax: 0041 (062) 888 70 10 [email protected] www.alfleth.com

China BalTec Machinery Shanghai Ltd Room 509, Yingjia Plaza Tower B No. 3008 Gu Dai Road 201100 Shanghai P.R. China

BalTec (UK) Ltd., BalTec House 1 Heron Industrial Estate Basingstoke Road, Spencers Wood, UK-Reading, Berkshire RG7 1PJ, Great Britain

Japan Tel.: 0055 11 99657 8485 0055 11 4492 5408 Fax: 0055 11 4584 7497 [email protected]. br

Bulgarien ALFLETH ENGINEERING AG Hardstrasse 4 CH-5600 Lenzburg Switzerland

Tel.: 0033 1 69 47 12 00 Mobile: 0033 688 84 8862 Fax: 0033 1 69 47 13 49 [email protected] www.baltec.fr

Grossbritannien, Irland Tel.: 0061 39 850 6666 Fax: 0061 39 852 1345 www.blissandreels.com.au

Baltik CLE Baltic Sära street 10 Peetri village Rae county 75312 Estonia

Schweden

BalTec France 11, rue Gustave Madiot ZA les Bordes FR-91070 Bondoufle France

Çağ-Kar Dış Ticaret Mümessillik Yunus Emre Mah.Veysel Karani Cad. No.143/C Yenidocan, Sancaktepe TR-34791 Istanbul Türkiye

Tel.: 0027 11 970 1930 /1/2/3 Fax: 0027 11 394 1132 Mobile: 0027 83 267 0857 [email protected] [email protected]

Tel.: 0066 (0) 2 732 1144 Fax: 0066 (0) 2 732 2350 Mobile: 0066 (0) 81 835 4449 [email protected]

Tel.: 0042 0563 034 502 Mobile: 0042 0604 311 822 Fax. 0042 0257 181 056 [email protected] www.ok-strojservis.cz

Tel.: 0090 216 430 89 29 Mobile: 0090 542 671 36 19 Fax: 0090 216 430 90 09 [email protected] [email protected] www.turkticaret.net/cag-kar

Ungarn

ALFLETH ENGINEERING AG Timirayzevskaya 1 RU-127422 Moskau Russia

Tel.: 007 495 661 90 57 Fax: 007 495 661 90 58 [email protected]

ALFLETH ENGINEERING AG Alfleth Rt. Magyarorszag Kft. Moricz Zsigmond körter 14.IV/1 HU-1117 Budapest Magyarország

Tel.: 0036 1 209 52 47 Fax: 0036 1 209 52 43 [email protected] [email protected]

USA, Kanada; Mexico BalTec Corporation 121 Hillpointe Drive Suite 900 Canonsburg, PA 1531, USA

803858.010/ENG

Tel.: 001 724 873 5757 Mobile: 011 412 400 6851 Fax: 001 724 873 5858 [email protected] www.baltecorporation.com

77

Appendix

78


803858.010/ENG


Index

12 Index A

N

Application limitations ................................................... 9 Automatic lubrication riveting spindle head ........... 38, 47

Noise...........................................................................11 Notes and symbols on the product................................9

B

O

Basic settings ............................................................. 20

Operator ........................................................................7 Original language of assembly instructions ...................6 Overview of maintenance work ...................................43

C CE conformity declaration........................................... 12

P

D Declaration of incorporation ........................................ 12 Declarations ................................................................ 12 Decommissioning ....................................................... 55 Dimensions drawing RNE 381 .................................... 15 Dimensions drawing RNE 381 for flange mounting .... 16 Disposal ...................................................................... 56

E Electrical power supply ................................................. 9 Emissions ................................................................... 11 Environmental conditions.............................................. 9

F Filling of hydraulic oil .................................................. 49 Filter hydraulic aggregate ........................................... 48 Foot switch ................................................................. 39 Form tool D = 20 with various lengths ........................ 26 Form tool designs and closing head shapes ............... 24

G General safety rules.................................................... 12

H Heating of hydraulic aggregate ................................... 19 Heating of riveting machine ........................................ 19 Hydraulic aggregate.................................................... 48 Hydraulic aggregate motor terminal box ..................... 49 Hydraulic aggregate RNE 381 details ......................... 14 Hydraulic hose lines.................................................... 49 Hydraulic oil ................................................................ 48

I Information and symbols............................................... 8 Initiator lower end position (bridging initiator) ............. 41 Initiator upper end position ......................................... 41 Intended use ............................................................... 10

M Maintenance and repair log ........................................ 53 Mechanical power supply ............................................. 9 Modifications ............................................................... 12

Personal safety equipment .........................................19 Personnel ......................................................................7 Personnel qualification ..................................................7 Piston and piston rod seals .........................................51 Polygon shaft .............................................................. 50 Possible machine settings ..........................................23 Power supply .............................................................. 11 Pressure pad............................................................... 34 Pressure pad dimensions drawing .............................. 35 Pressure/Force diagram .............................................21 Product life phases .......................................................7 Production of thrust piece and spring diagram 802296 ...............................................................................36

Q Questions or unclear points ..........................................6

R Recommended form tool materials ............................. 25 Recommended oils .....................................................48 Re-commissioning ......................................................55 Replaced parts ............................................................56 Replacing the form tool holder and pressure cup........28 Replacing the pressure cup with the removal device ..30 Rivet parameters...........................................................9 Riveting force adjustment ...........................................21 Riveting motor terminal box ........................................52 Riveting spindle...........................................................45 Riveting spindle advance speed adjustment ...............20 Riveting spindle head (form tool holder and pressure cup) ........................................................................44 Riveting stroke adjustment ..........................................20 Riveting to stroke limiting stop ....................................23 Riveting under high pressure ......................................23 Riveting under low pressure .......................................23 Riveting without stroke limiting stop ............................23 RNE 381 details ..........................................................13

S Schemata ....................................................................57 Setting up the riveting machine for a new workpiece ..22 Significance of the safety regulations ............................7

803858.010/ENG

79

Index


Spare parts lists .......................................................... 59 Standard form tool Ø20 with conical profile (270-431) 32 Standard form tool Ø20 with crowned profile (270-431) ............................................................................... 33 Standard form tool Ø20 with flat profile (270-431) ...... 31 Storage ....................................................................... 55

Two-hand operating unit .............................................51

T

W

Technical specifications riveting machine 381 ............ 17 Topping up the grease container ................................ 47

Warning and safety notices ...........................................8 Workplace ...................................................................19

80

U User ..............................................................................7

V Vibrations ....................................................................11

803858.010/ENG

Radial riveting machine RNE 381 - baltecorporation.com

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