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
Radial riveting machine RNE 381
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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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
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
Introduction
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5
Introduction 1
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
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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Safety regulations
2.3 2.3.1
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
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
See technical specifications, label
Rivet diameter
See technical specifications
Electrical power supply Rated voltage
See title page, label
Rated current
See technical specifications, label
Frequency
See title page, label
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Safety regulations
2.5 2.5.1
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
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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Safety regulations
2.8
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
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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Product description
3.4
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
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
Rated current riveting unit motor at 3 x 400V
A
4.0
Rated current riveting unit motor at 3 x 440V
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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Commissioning
4
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
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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Operation
5.2 5.2.1
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
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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Operation
5.3
Radial riveting machine RNE 381
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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Form tools
6 6.1
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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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Radial riveting machine RNE 381
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
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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
Radial riveting machine RNE 381
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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Form tools
6.5
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
Maintenance and repair work
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
Radial riveting machine RNE 381
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
Maintenance and repair work
X
X
43
Maintenance and repair work
8.2.1
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
8.2.2
Maintenance and repair work
Riveting spindle
803858.010/ENG
45
Maintenance and repair work
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
8.2.3
Maintenance and repair work
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
Maintenance and repair work
8.2.4
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
Maintenance and repair work
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
Maintenance and repair work
8.2.5
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
8.2.6
Maintenance and repair work
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
Maintenance and repair work
8.2.8
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
8.3
Maintenance and repair work
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Return line filter with aerating filter
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
Appendix
11.2 Spare parts lists 11.2.1 Machine body 381 Standard/HPP 852401-b
803858.010/ENG
59
Appendix
60
Radial riveting machine RNE 381
803858.010/ENG
Radial riveting machine RNE 381
Appendix
803858.010/ENG
61
Appendix
Radial riveting machine RNE 381
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
In-6kt low head M6x10 DIN 7984-8.8
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
In-6kt low head M5x12 DIN 7984-8.8
62
803858.010/ENG
Remarks
Radial riveting machine RNE 381
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.
Radial riveting machine RNE 381
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
Pipe fitting straight
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
Pipe fitting straight
366085
GE 15-PLR-ED
90
1
Pressure transmitters fixing
852070
RNS without pressure monitoring 85
2
Pipe fitting straight
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
Pos.
No.
Part Name
Part No.
Remarks
8
1
Form tool holder complete
838050
R = 100 / L = 68
9
1
Form tool holder complete
838051
R = 116 / L = 84
10
1
Form tool holder complete
838052
R = 132 / L = 100
11
1
Form tool holder complete
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
Form tool holder complete
838083
R = 170 / L = 138
21
1
Pressure cup
838084
R = 170 / L = 138
22
1
Form tool holder complete
838085
R = 191 / L = 159
23
1
Pressure cup
838062
R = 191 / L = 159
24
1
Form tool holder complete
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
11.2.4 Automatic lubrication 814340-u
68
803858.010/ENG
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
11.2.7 Pressure pad 270-431 838315-g
72
803858.010/ENG
Radial riveting machine RNE 381
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
Form tool holder complete
838051
R = 116 / L = 84
9
1
Form tool holder complete
838052
R = 132 / L = 100
10
1
Form tool holder complete
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
Form tool holder complete
838083
R = 170 / L = 138
23
1
Pressure cup
838084
R = 170 / L = 138
24
1
Form tool holder complete
838085
R = 191 / L = 159
25
1
Pressure cup
838062
R = 191 / L = 159
26
1
Form tool holder complete
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
Radial riveting machine RNE 381
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
Hydraulic aggregate complete
374919
3x575V, 60Hz
18
1
Hydraulic aggregate complete
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
Radial riveting machine RNE 381
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
Return line filter with aerating filter
379733
HF554-10129-AS-FG010-B17-GD-B-S-Z
51
1
Glycerine manometer
369806
Ø63 0 – 160bar 1/4B
52
1
Pressure limit cartridge
374946
DVP-2-10-SL max.70bar
54
2
Hydraulic hose
388067
L=2200mm
55
2
Pipe fitting straight
366041
GE 15-L/3/8"
56
1
Casing
852031
57
1
Tube
852032
58
1
Valve block
852122
59
1
Pressure limit cartridge
368108
60
1
Glycerine manometer
369809
61
1
Manometer screwed joint
369852
MAV 6-LR
62
2
Pipe fitting straight
366056
GE06LR1/4EDOMDCF
63
2
Pipe fitting straight
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
803858.010/ENG
Radial riveting machine RNE 381
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
Radial riveting machine RNE 381
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