Radial riveting machine RNE 181 HPP - baltecorporation.com · Radial riveting machine RNE 181 HPP Safety regulations 803835.006/ENG 7 2 Safety regulations 2.1 Term definitions The

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

803835.006/ENG

OPERATING INSTRUCTIONS

Radial riveting machine

RNE 181 HPP

reduced force max. 1.5 kN

803835.006/ENG

Machine no. xxx.xxxx

Power supply xxx

Introduction Radial riveting machine RNE 181 HPP

2 803835.006/ENG

Radial riveting machine RNE 181 HPP Introduction

803835.006/ENG 3

Contents

1 Introduction ............................................................................................................... 6

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

2.1 Term definitions ................................................................................................................................... 7

2.2 Significance of the safety regulations ................................................................................................. 7

2.3 Information and symbols ..................................................................................................................... 8 2.3.1 Warning and safety notices ............................................................................................................ 8 2.3.2 Notes and symbols on the product ................................................................................................ 9

2.4 Application limitations .......................................................................................................................... 9

2.5 Intended use ..................................................................................................................................... 10 2.5.1 Riveting machine/riveting unit ...................................................................................................... 10 2.5.2 Form tool ...................................................................................................................................... 10 2.5.3 Workpiece holders ....................................................................................................................... 11

2.6 Emissions .......................................................................................................................................... 11

2.7 Power supply ..................................................................................................................................... 11

2.8 General safety rules .......................................................................................................................... 12

2.9 Declarations ...................................................................................................................................... 12

3 Product description ................................................................................................ 13

3.1 RNE 181 reduced force HPP details ................................................................................................. 13

3.2 Dimensions drawing RNE 181 reduced force with path-measuring system HPP ............................ 14

3.3 Dimensions drawing RNE 181 reduced force with path-measuring system HPP for flange mounting .......................................................................................................................................................... 15

3.4 Technical specifications riveting machine 181 reduced force max. 1.5 kN ...................................... 16

4 Commissioning ....................................................................................................... 17

4.1 Introduction........................................................................................................................................ 17 4.1.1 Personnel requirements ............................................................................................................... 17

4.2 Riveting unit ...................................................................................................................................... 17

5 Operation ................................................................................................................. 18

5.1 Safety regulations riveting machine .................................................................................................. 18 5.1.1 Personal safety equipment .......................................................................................................... 18 5.1.2 Workplace .................................................................................................................................... 18 5.1.3 Heating of riveting machine ......................................................................................................... 18

5.2 Basic settings .................................................................................................................................... 19 5.2.1 Riveting stroke adjustment ........................................................................................................... 19 5.2.2 Riveting spindle advance speed adjustment ............................................................................... 20 5.2.3 Riveting spindle return speed adjustment .................................................................................... 20 5.2.4 Riveting force adjustment ............................................................................................................ 21

5.3 Setting up the riveting machine for a new workpiece ....................................................................... 22

5.4 Possible machine settings................................................................................................................. 23

6 Form tools ............................................................................................................... 24

6.1 Form tool designs and closing head shapes ..................................................................................... 24

6.2 Recommended form tool materials ................................................................................................... 25

6.3 Form tool D = 10 with various lengths............................................................................................... 26

6.4 Replacing the form tool holder and pressure cup ............................................................................. 27

6.5 Standard form tool Ø10 with flat profile (081-241) ............................................................................ 29

6.6 Standard form tool Ø10 with conical profile (081-241) ..................................................................... 30

6.7 Standard form tool Ø10 with crowned profile (081-241) ................................................................... 31

7 Options .................................................................................................................... 32


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7.1 Pressure pad .................................................................................................................................... 32 7.1.1 Pressure pad dimensions drawing .............................................................................................. 33 7.1.2 Production of thrust piece and spring diagram 802297 .............................................................. 34

7.2 Automatic lubrication riveting spindle head ...................................................................................... 36

7.3 Foot switch ....................................................................................................................................... 37 7.3.1 Function ....................................................................................................................................... 37 7.3.2 Dimensions drawing .................................................................................................................... 37 7.3.3 Technical specifications .............................................................................................................. 38

7.4 Initiator upper end position ............................................................................................................... 39

7.5 Initiator lower end position (bridging initiator) ................................................................................... 39

7.6 Riveting stroke limit switch unit NHE 181-231 ................................................................................. 40 7.6.1 My-Com Switch substitution ........................................................................................................ 42 7.6.2 Magnetic field sensor adjustment ................................................................................................ 43 7.6.3 Touch probe switching point NHE-E adjustment ........................................................................ 44 7.6.4 Spring prestress adjustment riveting stroke limit switch unit NHE .............................................. 45 7.6.5 Dimensions drawing RNE 181-231 HPP with NHE .................................................................... 46

7.7 Proportional pressure regulator ........................................................................................................ 47

8 Maintenance and repair work ................................................................................ 48

8.1 Introduction ....................................................................................................................................... 48 8.1.1 Safety regulations ........................................................................................................................ 48 8.1.2 Personnel requirements .............................................................................................................. 48

8.2 Overview of maintenance work ........................................................................................................ 49 8.2.1 Riveting spindle head (form tool holder and pressure cup) ........................................................ 50 8.2.2 Riveting spindle ........................................................................................................................... 51 8.2.3 Automatic lubrication riveting spindle head (option) ................................................................... 53 8.2.4 Air maintenance unit.................................................................................................................... 54 8.2.4.1 Mist oiler adjustment ...............................................................................................................55 8.2.5 Polygon shaft ............................................................................................................................... 56 8.2.6 Two-hand operating unit ............................................................................................................. 57 8.2.7 Piston and piston rod seals ......................................................................................................... 57 8.2.8 Riveting motor terminal box ........................................................................................................ 58

8.3 Maintenance and repair log .............................................................................................................. 59

9 Decommissioning, Storage .................................................................................... 61

9.1 Decommissioning ............................................................................................................................. 61

9.2 Storage ............................................................................................................................................. 61

9.3 Re-commissioning ............................................................................................................................ 61

10 Disposal ................................................................................................................... 62

10.1 Introduction ....................................................................................................................................... 62 10.1.1 Personnel requirements .............................................................................................................. 62

10.2 Disposal ............................................................................................................................................ 62 10.2.1 Replaced parts ............................................................................................................................ 62 10.2.2 Mineral oils .................................................................................................................................. 62 10.2.3 Riveting unit ................................................................................................................................. 62

11 Appendix ................................................................................................................. 63

11.1 Schemata ......................................................................................................................................... 63 11.1.1 Pneumatic diagram with air maintenance unit 181 reduced force, 803541 ................................ 63 11.1.2 Pneumatic diagram 181 reduced force with proportional pressure regulator 803584 ................ 64 11.1.3 Pneumatic diagram for automatic lubrication 802417 ................................................................. 65

11.2 Spare parts lists ................................................................................................................................ 66 11.2.1 Machine body 181 reduced force Standard/HPP 825403-b ....................................................... 66 11.2.2 Riveting head 081-241 814310-h ................................................................................................ 70 11.2.3 Electric motor 181 825320-m ...................................................................................................... 72 11.2.4 Pneumatics 181 STF/HPP 825328-n .......................................................................................... 73 11.2.5 Automatic lubrication 814340-u ................................................................................................... 76

Radial riveting machine RNE 181 HPP Introduction

803835.006/ENG 5

11.2.6 Foot switch 813345-d ................................................................................................................... 78 11.2.7 Two-hand operating unit 814350-d .............................................................................................. 79 11.2.8 Pressure pad 081-241 814315-d ................................................................................................. 80 11.2.9 Path-measuring system HPP-181, 825408-c .............................................................................. 82 11.2.10 Riveting stroke limit switch unit NHE-U 181-231, 825290.01 ...................................................... 84 11.2.11 Riveting stroke limit switch unit NHE-H 181-231, 825290.03-a ................................................... 85 11.2.12 Riveting stroke limit switch unit NHE-E 181-231, 825290.07-a ................................................... 86 11.2.13 Riveting stroke limit switch unit NHE-Combi 181-231, 825290.09-a ........................................... 87 11.2.14 Riveting stroke limit switch unit (NHE) basic unit 181 – 431, 826098 ......................................... 88 11.2.15 Proportional pressure regulator 181/231/281 868191 ................................................................. 89

12 Index......................................................................................................................... 92


6 803835.006/ENG

1 Introduction

We are certain that you have made the right choice with our product and thank you for your trust.

For your personal safety

Before carrying out any activities on or with the riveting machine, please carefully read these operating instructions first, in particular the chapter on "Safety regulations".

Application area of these operating instructions

These operating instructions describe the riveting machine and provide all information required for safe operation and maintenance of functionality. Please keep these operation instructions available at all times for all persons involved with the riveting machine.

Questions or unclear points

Please contact immediately if you have any questions or unclear points:

- BalTec Maschinenbau AG, Obermattstrasse 65 CH – 8330 Pfäffikon ZH

- BalTec – distributors (see representatives list in the appendix)

Please provide them with the document and page numbers located in the footer and the machine number listed on the title page of operating instructions.

Original language of assembly instructions

These assembly instructions was originally written in German language.

——

© Copyright BalTec Maschinenbau AG – Pfäffikon 2010

Radial riveting machine RNE 181 HPP Safety regulations

803835.006/ENG 7

2 Safety regulations

2.1 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.

Safety regulations Radial riveting machine RNE 181 HPP

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2.3 Information and symbols

2.3.1 Warning and safety notices

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

CAUTION

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

WARNING

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

DANGER

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

NOTICE

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

CAUTION

To warn of material damage only.


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2.3.2 Notes and symbols on the product

The following information and symbols are located on the riveting machine:

Warning signs

Danger of hand injuries

Mandatory sign

Wear safety goggles

Mandatory sign

Wear gloves

2.4 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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2.5 Intended use

2.5.1 Riveting machine/riveting unit

BalTec riveting machines are intended to form positive connections by cold forming of connection elements. The connection element (rivet) can either be a separate element or a specially shaped deformation zone on the workpiece itself. The connection is created in that a riveting tool (form tool) creates a closing head on the connection element.

Following activation types are permitted to actuate the riveting process:

a) Permanent activation with two-hand switching for:

Manual charging

Stroke H greater than 6 mm

Stroke speed greater than 30 mm/s

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

Workpiece charging with handling device

Stroke H smaller than 6 mm

Stroke speed smaller than 30 mm/s

The riveting machines are laid out for use in commercial or industrial production; e.g.

a) As machining station in a production line

b) As stand-alone workplace or production cell

The riveting units are laid out for installation in any spatial position: e.g.

a) Vertical, with direction of action from top to bottom or bottom to top

b) Horizontal

2.5.2 Form tool

WARNING

Form tool breaks if an inappropriate material is used!

Eye injuries, cutting damages!

Form tool is to produce according to our specifications: material, heat treatment, geometry (see Chapter "Form tools").


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2.5.3 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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2.8 General safety rules

Modifications

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

2.9 Declarations

CE conformity declaration

A CE-compliant riveting machine is marked with a CE rating plate. The standards used to check conformity are listed in the CE conformity declaration.

The CE conformity declaration is included in the delivery documentation.

Declaration of incorporation

When being installed in other machines and/or for operation with a third party control unit, a non CE-compliant riveting machine cannot be commissioned until it is ensured that it meets the provisions of the machine directive 2006/42/EG.

The declaration of incorporation is included in the delivery documentation.

Radial riveting machine RNE 181 HPP Product description

803835.006/ENG 13

3 Product description

3.1 RNE 181 reduced force HPP details

Item Name Item Name

1 Riveting stroke adjustment 14 Water separator, sight glass

2 Clamping screw for riveting stroke adjustment

15 Water separator, drain valve

3 Lubricator nipple 16 Restrictor valve for riveting spindle advance speed

4 Supply air 17 Initiator lower end position (option)

5 Exhaust air 18 Pressure regulator valve

6 Riveting spindle head 19 Manometer

7 Form tool 27 Path-measuring system HPP

12 Air connection 28 Initiator upper end position (option)

13 Oil sight glass 32 Restrictor valve for riveting spindle return speed

Product description Radial riveting machine RNE 181 HPP

14 803835.006/ENG

3.2 Dimensions drawing RNE 181 reduced force with path-measuring system HPP

Drawing no. 825400.42

Free height „H“ see chapter ”Form tool D=10 with various lengths“

Radial riveting machine RNE 181 HPP Product description

803835.006/ENG 15

3.3 Dimensions drawing RNE 181 reduced force with path-measuring system HPP for flange mounting

Drawing no. 825400.45

Free height „H“ see chapter ”Form tool D=10 with various lengths“

Product description Radial riveting machine RNE 181 HPP

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3.4 Technical specifications riveting machine 181 reduced force max. 1.5 kN

Maximum rivet shaft diameter (solid shaft rivet, steel 370 N/mm

2)

Ø 2

Riveting unit motor, driving power at 50Hz kW 0.25

Riveting unit motor, driving power at 60Hz kW 0.30

Riveting unit motor, rpm at 50Hz min-1

1330

Riveting unit motor, rpm at 60Hz min-1

1595

Rated current at 1 x 220V A 2.5




Pneumatics operating pressure bar 2 - 6

Thread size compressed air connection (air maintenance unit STF)

G ⅜“

Thread size compressed air connection (air maintenance unit)

G ¼”

Max. riveting force at 6 bar kN 1.5

Max. permissible riveting time per cycle sec 10

Tool stroke (stroke limiting stop-adjustment range) mm 5 - 30

Cylinder volume at maximum stroke cm3 78.25

Weight of riveting machine without control unit kg 55

Weight of riveting machine with control unit kg 65

Weight of riveting unit kg 30

Radial riveting machine RNE 181 HPP Commissioning

803835.006/ENG 17

4 Commissioning

4.1 Introduction

4.1.1 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.

Operation Radial riveting machine RNE 181 HPP

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5 Operation

5.1 Safety regulations riveting machine

5.1.1 Personal safety equipment

All user are obliged to wear the following personal safety equipment for all work:

Tightly fitting working clothes

Safety goggles

Gloves

5.1.2 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!

Radial riveting machine RNE 181 HPP Operation

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5.2 Basic settings

5.2.1 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!


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5.2.2 Riveting spindle advance speed adjustment

The advance speed of the riveting spindle can be adjusted with the restrictor valve.

Procedure:

Reducing the advance speed:

Rotate the level control of the restrictor valve clockwise

Increasing the advance speed:

Rotate the level control of the restrictor valve counter-clockwise

NOTICE

To have easy access to the restrictor valve, move the riveting unit up to the top position!

5.2.3 Riveting spindle return speed adjustment

The return speed of the riveting spindle can be adjusted with the restrictor valve.

Procedure

Reducing the return speed:

Rotate the level control of the restrictor valve clockwise

Increasing the return speed:

Rotate the level control of the restrictor valve counter-clockwise

NOTICE

To have easy access to the restrictor valve, move the riveting unit up to the top position!


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5.2.4 Riveting force adjustment

The riveting force (operating pressure) is adjusted at the pressure regulator of the air maintenance unit.

Procedure:

1. Pull the turning handle up out of the detent

2. Set the required operating pressure

3. The value set is displayed by the manometer

The operating pressure set determines the riveting force at the form tool (see pressure/force diagram).

Pressure/force diagram

P = operating pressure F = riveting force

NOTICE

The operating pressure can be set between 1-6 bar. To ensure good functionality, we recommend that the minimum operating pressure of 2 bar is not undershot. The maximum operating pressure is 6 bar and must not be exceeded!

0

1

2

3

4

5

6

0 0.5 1 1.5

F [kN]

P[b

ar]


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5.3 Setting up the riveting machine for a new workpiece

Before setting up for a new riveting job, the following requirements must be met:

1. Suitable form tool for the rivet and closing head to be produced

2. Form tool length suitable for calotte radius of pressure cup (Rp) in the currently installed form tool holder

NOTICE

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

3. Rivet holder or workpiece carrier must be set up centrically to the riveting spindle axis and fixed onto the machine table

The following settings must always be made in the control unit "Setup operation" so that the procedure can be interrupted at any time:

1. Insert workpiece

2. Adjust the height of the riveting machine in the stand so that the distance of the form tool to the rivet is smaller than the maximum achievable spindle stroke. If a short cycle time is desired, this distance to the workpiece can be reduced as long as the necessary distance required to insert the workpiece is maintained.

3. Set the required dimension for the rivet path with the stroke limiting stop

NOTICE

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

4. At the same time, incrementally adjust the riveting force setting (via pressure regulator) and riveting spindle advance speed (via restrictor valve) to obtain the required results

If the workpieces evidence spreading over the height, the stroke limitation may be an obstacle. In this case, the stroke limiting stop should be set slightly lower than necessary. The actual riveting path is then only limited by the termination of the specified riveting time.

NOTICE

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


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5.4 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.

Form tools Radial riveting machine RNE 181 HPP

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6 Form tools

6.1 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".

Radial riveting machine RNE 181 HPP Form tools

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6.2 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

%

Cr

%

Mon.

%

V

%

W

%

0.84-0.92

0.45 0.40 0.030 0.030 3.80-4.50

4.70-5.20

1.70-2.00

6.00-6.70

Application Preparation tempered materials

Form tool designs Normal and special designs


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6.3 Form tool D = 10 with various lengths

Standard form tools with shaft diameter D=10 can be replaced by hand. They are held with a permanent magnet.

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!

For longer and therefore heavier form tools, the use of an O-ring (9.25x1.78mm) inserted into the groove in the form tool holder can provide a better hold.

Item Name

1 Form tool axis

2 Pressure cup

3 Form tool holder

4 Magnet

6 Form tool

Machines Type

Radius Rp [mm]

Form tool length

Ls [mm ± 0.1]

Shaft Ds [mm]

Angle

Free height H

[mm]

081 170 181 220 231 241

65 39

10g6

6° 02´ 18

80 54 4° 47´ 33

100 74 3° 44´ 53

120 94 3° 04´ 73

132 106 2° 46´ 85


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6.4 Replacing the form tool holder and pressure cup

Item Name

1 Internal ring gear

2 Pressure cup

3 Form tool holder

4 Connection piece

5 Screw M4x12

6 Pressure spring

7 Cap

8 Form tool

Procedure:

1. Pull form tool out of riveting head

2. 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. Once the cap is removed, pull the form tool holder and pressure spring out of the riveting head

4. Pull the pressure cup out of the centring in the connection piece using the screws M4x45 provided in the machine accessories and insert a new pressure cup

CAUTION

The screws M4x45 must not be used to push the pressure cup off the internal ring gear. Contact surface of internal ring gear will be damaged!

5. Grease the form tool holder with Klübersynt GE 46-1200 (also see Chapter "Maintenance and repair work")

6. 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

NOTICE

When installing the pressure spring in the riveting machine models 081, 170, 181, 220, 231 and 241, check that the tapering end of the pressure spring ends up positioned in the cap!


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6.5 Standard form tool Ø10 with flat profile (081-241)

Ls = 39 ± 0.1 Ls = 54 ± 0.1 Ls = 74 ± 0.1

Article no.

Øds

± 0.1 α° L2

Article no.

Øds

± 0.1 α° L2

Article no.

Øds

± 0.1 α° L2

880501* 1.0 15-45 880541 1.0 15-45 880581 1.0 15-45

880502* 1.5 15-45 880542 1.5 15-45 880582 1.5 15-45

880503* 2.0 15-45 880543 2.0 15-45 880583* 2.0 15-45

880504* 2.5 15-45 880544 2.5 15-45 880584 2.5 15-45

880505* 3.0 15-45 880545 3.0 15-45 880585* 3.0 15-45

880506* 3.5 15-45 880546 3.5 15-45 880586 3.5 15-45

880507* 4.0 15-45 880547* 4.0 15-45 880587* 4.0 15-45

880508* 4.5 15-45 880548 4.5 15-45 880588 4.5 15-45

880509* 5.0 15-45 880549 5.0 15-45 880589* 5.0 15-45

880510* 5.5 15-45 880550 5.5 15-45 880590 5.5 15-45

880511* 6.0 15-45 880551* 6.0 15-45 880591* 6.0 15-45

880512* 6.5 15-45 880552 6.5 15-45 880592 6.5 15-45

880513* 7.0 15-45 880553 7.0 15-45 880593* 7.0 15-45

880514* 7.5 15-45 880554 7.5 15-45 880594 7.5 15-45

880515* 8.0 15-45 880555* 8.0 15-45 880595* 8.0 15-45

880516* 8.5 15-45 880556 8.5 15-45 880596 8.5 15-45

880517* 9.0 15-45 880557 9.0 15-45 880597* 9.0 15-45

880518* 9.5 15-45 880558 9.5 15-45 880598 9.5 15-45

880519* 10.0 880559* 10.0 880599* 10.0

880520* 10.5 25 880560 10.5 40

880521* 11.0 25 880561 11.0 40

880522* 11.5 25 880562 11.5 40

880523* 12.0 25 880563 12.0 40

880524* 12.5 25

880525* 13.0 25

880526* 13.5 25

880527* 14.0 25

880528* 14.5 25

880529* 15.0 25

* = available from stock (α = 15°)


30 803835.006/ENG

6.6 Standard form tool Ø10 with conical profile (081-241)

Ls = 39 ± 0.1 Ls = 54 ± 0.1 Ls = 74 ± 0.1

Article no.

Øds ± 0.1

α° β°

± 30’ Rs L2 L3

Article no.

Øds ± 0.1

α° β°

± 30’ Rs L2 L3

Article no.

Øds ± 0.1

α° β°

± 30’ Rs L2 L3

881501* 1.0 15-45 5 3 881541 1.0 15-45 4 4 881581 1.0 15-45 3 5

881502* 1.5 15-45 5 4 881542 1.5 15-45 4 5 881582 1.5 15-45 3 7

881503* 2.0 15-45 5 6 881543 2.0 15-45 4 7 881583 2.0 15-45 3 10

881504* 2.5 15-45 5 7 881544 2.5 15-45 4 9 881584 2.5 15-45 3 12

881505* 3.0 15-45 5 9 881545* 3.0 15-45 4 11 881585* 3.0 15-45 3 14

881506* 3.5 15-45 5 10 881546 3.5 15-45 4 13 881586 3.5 15-45 3 17

881507* 4.0 15-45 5 11 881547 4.0 15-45 4 14 881587 4.0 15-45 3 19

881508* 4.5 15-45 5 13 881548 4.5 15-45 4 16 881588 4.5 15-45 3 21

881509* 5.0 15-45 5 14 881549* 5.0 15-45 4 18 881589* 5.0 15-45 3 24

881510* 5.5 15-45 5 16 881550 5.5 15-45 4 20 881590 5.5 15-45 3 26

881511* 6.0 15-45 5 17 881551 6.0 15-45 4 22 881591 6.0 15-45 3 29

881512* 6.5 15-45 5 19 881552 6.5 15-45 4 23 881592 6.5 15-45 3 31

881513* 7.0 15-45 5 20 881553* 7.0 15-45 4 25 881593* 7.0 15-45 3 33

881514* 7.5 15-45 5 22 881554 7.5 15-45 4 27 881594 7.5 15-45 3 36

881515* 8.0 15-45 5 23 881555 8.0 15-45 4 29 881595 8.0 15-45 3 38

881516* 8.5 15-45 5 24 881556 8.5 15-45 4 30 881596 8.5 15-45 3 41

881517* 9.0 15-45 5 26 881557* 9.0 15-45 4 32 881597* 9.0 15-45 3 43

881518* 9.5 15-45 5 27 881558 9.5 15-45 4 34 881598 9.5 15-45 3 45

881519* 10.0 5 29 881559 10.0 4 36 881599* 10.0 3 48

881520* 10.5 5 30 22 25 881560 10.5 4 38 37 40

881521* 11.0 5 32 22 25 881561 11.0 4 39 37 40

881522* 11.5 5 33 22 25 881562 11.5 4 41 37 40

881523* 12.0 5 34 22 25 881563 12.0 4 43 37 40

881524* 12.5 5 36 22 25

881525* 13.0 5 37 22 25

881526* 13.5 5 39 22 25

881527* 14.0 5 40 22 25

881528* 14.5 5 42 22 25

881529* 15.0 5 43 22 25

881535 18 5 52 22 25



803835.006/ENG 31

6.7 Standard form tool Ø10 with crowned profile (081-241)

Ls = 39 ± 0.1 Ls = 54 ± 0.1 Ls = 74 ± 0.1

Article no.

Øds ± 0.1

α° Ro ± 0.1

Bt ± 0.05

L2 Article

no. Øds ± 0.1

α° Ro ± 0.1

Bt ± 0.05

L2 Article

no. Øds ± 0.1

α° Ro ± 0.1

Bt ± 0.05

L2

882501 1.0 15-45 0.8 0.05 882541 1.0 15-45 1.2 0.03 882581 1.0 15-45 1.5 0.03

882502* 1.5 15-45 1.7 0.08 882542 1.5 15-45 2.2 0.06 882582 1.5 15-45 2.8 0.05

882503* 2.0 15-45 2.6 0.12 882543 2.0 15-45 3.3 0.09 882583 2.0 15-45 4.2 0.07

882504* 2.5 15-45 3.5 0.15 882544 2.5 15-45 4.4 0.12 882584 2.5 15-45 5.6 0.10

882505* 3.0 15-45 4.4 0.19 882545 3.0 15-45 5.5 0.15 882585 3.0 15-45 7.0 0.12

882506* 3.5 15-45 5.4 0.22 882546 3.5 15-45 6.8 0.17 882586 3.5 15-45 8.5 0.14

882507* 4.0 15-45 6.4 0.25 882547 4.0 15-45 8.0 0.20 882587* 4.0 15-45 10.0 0.16

882508* 4.5 15-45 7.5 0.28 882548 4.5 15-45 9.2 0.23 882588 4.5 15-45 11.6 0.18

882509* 5.0 15-45 8.5 0.31 882549 5.0 15-45 10.5 0.25 882589* 5.0 15-45 13.2 0.20

882510* 5.5 15-45 9.5 0.34 882550 5.5 15-45 12.0 0.27 882590 5.5 15-45 15.0 0.22

882511* 6.0 15-45 10.7 0.37 882551 6.0 15-45 13.2 0.30 882591* 6.0 15-45 16.6 0.24

882512* 6.5 15-45 11.8 0.40 882552 6.5 15-45 14.6 0.32 882592 6.5 15-45 18.5 0.25

882513* 7.0 15-45 13.0 0.42 882553 7.0 15-45 16.2 0.34 882593 7.0 15-45 15.3 0.36

882514* 7.5 15-45 14.2 0.44 882554 7.5 15-45 17.4 0.36 882594 7.5 15-45 22.0 0.29

882515* 8.0 15-45 15.4 0.47 882555 8.0 15-45 19.2 0.38 882595* 8.0 15-45 24.0 0.30

882516* 8.5 15-45 16.7 0.49 882556 8.5 15-45 20.8 0.39 882596 8.5 15-45 26.0 0.32

882517* 9.0 15-45 18.0 0.52 882557 9.0 15-45 22.5 0.41 882597 9.0 15-45 28.0 0.33

882518* 9.5 15-45 19.4 0.54 882558 9.5 15-45 24.0 0.43 882598 9.5 15-45 30.2 0.34

882519* 10.0 20.5 0.56 882559 10.0 24.5 0.44 882599* 10.0 32.0 0.35

882520* 10.5 22.0 0.57 25 882560 10.5 27.2 0.46 25

882521* 11.0 23.5 0.59 25 882561 11.0 29.1 0.47 25

882522* 11.5 25.0 0.61 25 882562 11.5 31.0 0.49 25

882523* 12.0 26.7 0.62 25 882563 12.0 33.0 0.50 25

882524* 12.5 28.4 0.64 25

882525* 13.0 30.2 0.65 25

882526* 13.5 31.9 0.66 25

882527* 14.0 33.8 0.68 25

882528* 14.5 35.8 0.69 25

882529* 15.0 37.8 0.70 25


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!

Options Radial riveting machine RNE 181 HPP

32 803835.006/ENG

7 Options

7.1 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

Radial riveting machine RNE 181 HPP Options

803835.006/ENG 33

7.1.1 Pressure pad dimensions drawing

Machine type

081 170/181 220/231 241 270/281 331 381/431

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 Application-

specific Application-

specific

Application-specific





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”

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


34 803835.006/ENG

7.1.2 Production of thrust piece and spring diagram 802297

Spring diagram

F (daN) spring force Fmax. 1000 daN

f (mm) travel

* Travel f = 0.75h do not exceed if possible

I 7 disk springs 45x22.4x1.25 (simple)

II 10 disk springs 45x22.4x1.25 (double)

III 6 disk springs 45x22.4x2.5 (simple)


803835.006/ENG 35

Example: a and b sought for pre-stress force

Fv = 130 daN for I

Fv = 220 daN for II

Fv = 460 daN for III

Spring combination Force at 0.75h

I a=8.9

A travel of 4.5 (13.4-8.9) remains for b -> F 190 daN

II a=6.7


III a=6.6


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


36 803835.006/ENG

7.2 Automatic lubrication riveting spindle head

The automatic lubrication is recommended mainly for machines and units that are installed in automatic systems and are operated in multi-shifts. It is however also suitable for manual workplaces to ensure regular relubrication of form tool holders and pressure cups.

Two machines or units (e.g. RND) can be lubricated simultaneously with a second metering valve. The distance between both machines or units should however not exceed more than 1 meter.

A constant air pressure of 6 bar is necessary to operate the device.

Setting the grease volume

The riveting spindle head is default supplied with approx. 6mm

3 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 approx. 1mm

3.

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".


803835.006/ENG 37

7.3 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


38 803835.006/ENG

7.3.3 Technical specifications

Type F1-U1Z UN Type F1-U2ZD UN

Part number 606.1600.006 606.1700.008

Wiring diagram

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. 50/min.

Mech. service life - number of cycles 10 x 106 10 x 10

6

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


803835.006/ENG 39

7.4 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

with path-measuring system HPP

7.5 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.


40 803835.006/ENG

7.6 Riveting stroke limit switch unit NHE 181-231

The riveting stroke limit switch unit is used for rivet projection control. As option the following riveting stroke limit switch units (view without cover) are available:

NHE-U (825290.01)

Projection measuring device with My-Com switch

NHE-H (825290.03)

Projection measuring device with magnetic field sensor

Application: for rivet projection measurement U Application: for riveting modes with control variable H (driven head height)

NHE-E (825290.07)

Projection measuring device with My-Com switch and adjustment spindle

NHE-Combi (825290.09)

Combined projection measuring device with My-Com switch and magnetic field sensor

Application: e.g. for riveting modes with control variable E (riveting spindle path from TDC to riveting end)

Application: for rivet projection measurement U or riveting modes with control variable H (driven head height)

NOTICE

NHE-H and NHE-Combi can only be used in connection with Process-Controller HPP-25!


803835.006/ENG 41

At customer’s request the riveting stroke limit switch unit NHE can be equipped with a mechanic organ of touch.

Item Name Item Name

1 Slider (carriage) 3 Touching bush

2 Touching lever

For further information, such as function and settings, refer to the operating instructions of “Process-Controller HPP-25 Autocompensation“.


42 803835.006/ENG

7.6.1 My-Com Switch substitution

Item Name Item Name

1 Turning lever 4 Fitting bolt

2 My-Com-Switch 5 Mounting nut

3 Slide 6 Slider (guiding slide)

Procedure

1. Undo mounting nut and remove existent My-Com-Switch

2. Screw in so long new My-Com Switch as the lower thread edge of My-Com-Switch is mounted flush with the slide (see figure right)

3. Fix My-Com-Switch with mounting nut

After substitution effect following test: Proceed slider till My-Com-Switch switches at turning lever (opener switching point).

Maintenance

If necessary, grease between turning lever, slider and fitting bolt.


803835.006/ENG 43

7.6.2 Magnetic field sensor adjustment

Adjust magnetic field sensor with feeler gauge (nominal dimension 0.1 – 0.6mm).

NHE-H NHE-Combi

Item Name Item Name

1 Magnetic field sensor 3 Plate

2 Magnetic tape 4 Slider


44 803835.006/ENG

7.6.3 Touch probe switching point NHE-E adjustment

The riveting stroke limit switch unit NHE-E is required for operation in riveting modes N1, N2, N3, N4 and T14 of Process-Controller HPP-25.

Item Name Item Name

1 Screw 3 Slide

2 Rotary knob with scale 4 Edge for reading

Procedure:

1. Undo screw item 1

2. Turn rotary knob item 2 and adjust rivet end

Riveting lower: Turn rotary knob clockwise

Riveting higher: Turn rotary knob counterclockwise

3. Retighten screw item 1


803835.006/ENG 45

7.6.4 Spring prestress adjustment riveting stroke limit switch unit NHE

Item Name

1 Threaded pin

2 Spring

3 Slider (guiding slide)

The spring prestress is set from the bottom by a threaded pin in the guiding slide.

Set values

Spring rate: 1.99N/mm Spring prestress 9 – 25mm (18N – 50N)


46 803835.006/ENG

7.6.5 Dimensions drawing RNE 181-231 HPP with NHE

NHE-U/NHE-H/NHE-E

NHE-Combi


803835.006/ENG 47

7.7 Proportional pressure regulator

Function and application

The Proportional pressure regulator has been designed for regulating a pressure proportional to a specified set point value. A built-in pressure sensor records the pressure at the working line and compares this value with the set point value. If the actual value differs from the set point value, the regulating valve is actuated further until the output pressure reaches the set point value.

For further information, such as settings and connection diagrams refer to the operating instructions of Process-Controller.

Maintenance and repair work Radial riveting machine RNE 181 HPP

48 803835.006/ENG

8 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.


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

Radial riveting machine RNE 181 HPP Maintenance and repair work

803835.006/ENG 49

8.2 Overview of maintenance work

Assembly Type of maintenance Maintenance interval

(whichever is reached first)

Check

Relu

brication

Rem

ova

l

Cle

anin

g

New

lubrica

tio

n

Toppin

g u

p

Em

pty

ing

Repla

cem

ent

Every

40h o

r w

eekly

Every

100

0h o

r ann

ua

lly

Every

500

0h o

r 2 y

ears

Each t

ime r

iveting

un

it is

dis

ma

ntled

Riveting spindle head (form tool holder and pressure cup)

X X X

Riveting spindle X X X X X

Automatic lubrication riveting spindle head (option)

X When the corresponding indication appears on the

control unit display

Air maintenance unit X X X X

Polygon shaft X X X

Two-hand operating unit

X X

Piston and piston rod seals

X X

Riveting motor terminal box

X X


50 803835.006/ENG

8.2.1 Riveting spindle head (form tool holder and pressure cup)

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 Maintenance activity Grease type Interval

Pressure cup/form tool holder

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

Klübersynth GE 46-1200

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.

Clean, check for wear, relubricate

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

Form tool holder spherical plain bearing

Clean and check for wear, relubricate, replace if necessary

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

7


803835.006/ENG 51

8.2.2 Riveting spindle


52 803835.006/ENG

Riveting spindle maintenance schedule

Item Name

Maintenance activity Grease type

Comments

Cle

an a

nd c

heck for

wear,

rep

lace if

necessary

Dis

man

tle

Repla

cem

ent

Lubricate

Klü

ber-

Sta

bura

gs

NB

U 8

EP

Mob

il D

TE

24

4 Guide sleeve X X

7 Eccentric sleeve X

16 Internal ring gear X X X

17 Eccentric shaft X X X

18 Washer X

20 Buffer disc X

33 Axial ball bearing X X

34 Axial needle ring X X

35 Needle bearing X X

37 Needle ring X X

38 I.D. seal X X

40 I.D. seal X X

41 O.D. seal X X

42 Damping sealing ring X X

43 Compensating washer X X

44 Compensating washer X X

Item 44 must be centered on the damping piston item 3 during assembly (grease item 44 with Klüber-Staburags NBU 8 EP to make it easier)

45 O-Ring X X

48 O-Ring X X

64 Counter washer X

87 Shaft & housing locating wash. 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)!


803835.006/ENG 53

8.2.3 Automatic lubrication riveting spindle head (option)

Item Name Item Name

1 Injection lubricator (metering valve) 7 Initiator

2 Lubricant line 8 Container cover

3 Solenoid valve 9 Pistons

4 Screwed connection 10 Pressure control valve

5 Plug screw 11 Compressed air hose

6 Grease container (27.6 cm3)

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!

http://www.seton.ch/D10304400/Symbol-Warnschilder-Warnung-vor-Ueberdruck.html


54 803835.006/ENG

8.2.4 Air maintenance unit

081, 181, 231, 281 181 STF, 231 STF, 281 STF, 331, 331 STF

331, 331 STF

Item Name Item Name

1 Filter / water separator 4 Exhaust air filter

2 Oil tank 5 Filter element

3 Drain valve 6 Oil filler screw

Air maintenance unit maintenance schedule

Item Maintenance activity Oil type Interval

1

Check water level, drain water via drain valve when necessary.

Notice: The condensate level must never exceed the maximum mark otherwise water with compressed air would be entrained to the control elements!

Every 40h or weekly

2

Check oil level, top up if necessary

Oil filler air maintenance unit 081 – 281:

Stop compressed air supply to air maintenance unit (oil filler under pressure not possible!)

Unscrew oil tank

Top up oil to the mark

Oil filler air maintenance unit 331, 181 – 331 STF:

Possible during operation, system has not to be unpressurized

Undo slowly oil filler screw (pressure decrease in oil tank)

Top up oil to the mark

Retighten oil filler screw

See table for recommended oils

Every 40h or weekly

4 Replace filter element Annually


803835.006/ENG 55

Oils recommended for the air maintenance unit

Manufacturer Name

BP ENERGOL RD-E 46 (ISO)

CHEVRON (only available in USA) ARIES ISO-VG 46

ESSO NUTO H32

MOBIL MOBIL DTE 24

SHELL TORCULA Oil 32 (ISO)

TEXACO (only available in Europe) ARIES ISO-VG 32

VALVOLINE ATO 46 or ATO 22 SYNTH

8.2.4.1 Mist oiler adjustment

Item Name

1 Adjustment screw

2 Mist oiler

Use the adjustment screw to set the desired oil quantity. At delivery the oiler is opened by 1½ turn clockwise.

Increasing the oil quantity = turn the adjustment screw counterclockwise

Decreasing the oil quantity = turn the adjustment screw clockwise

If oil escapes out of the pneumatic valve the quantity of oil could be reduced.


56 803835.006/ENG

8.2.5 Polygon shaft

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

NOTICE

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


803835.006/ENG 57

8.2.6 Two-hand operating unit

The two-hand operating unit must be checked regularly, at least once a year, by an expert provided by the operator. This check must cover:

1. The secure function of the two-hand operating unit

2. The condition of the two-hand operating unit components

3. The interaction of the two-hand operating unit with the riveting machine control unit

The test results must be documented in a report to be signed by the tester. The report must be retained.

Safety inspection

After every change in working procedures, e.g tool change, change to activation type "Two-hand operating unit", additions of further safety equipment, the following must be checked:

1. That the two-hand operating unit required for safety is switched on and functional

2. That the two-hand operating unit and exposed connection lines are visually undamaged

3. That the necessary safety distance is complied with

Check list for two-hand operating unit check Yes No

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

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

8.2.7 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).


58 803835.006/ENG

8.2.8 Riveting motor terminal box

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

DANGER

Touching of live parts on the open terminal box!

Electric shock!

Isolate the electrical power supply! Electrical commissioning has to be made only by a trained authorised electrician!


803835.006/ENG 59

8.3 Maintenance and repair log

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

Effective operating hours (shown on the control unit display)

Tick in cycle column

Work carried out

Name and date

Archive the completed forms.

Example form

Maintenance log for

Machine : RN 231 Machine no.: 231.9999

Work carried out

Cou

nte

r d

isp

lay:

Op

era

ting

hou

rs

Riv

eting u

nit

dis

ma

ntled

Weekly

or

every

40

opera

tin

g h

ours

Half-y

earl

y o

r every

500 o

pera

tin

g h

ours

Yearl

y o

r every

10

00

opera

tin

g h

ours

Every

2 y

ears

or

5000

opera

tin

g h

ours

Work Carried out by Date

00050 X 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

05060 X X Riveting machine checked S.Template 24.10.05


60 803835.006/ENG

Maintenance and repair log

Maintenance log for

Machine: Machine no.:

Work carried out

Co

un

ter

dis

pla

y:

Op

era

ting

hou

rs

Riv

eting u

nit

dis

ma

ntled

Weekly

or

every

40

opera

tin

g h

ours

Half-y

earl

y o

r every

500 o

pera

tin

g h

ours

Yearl

y o

r every

10

00

opera

tin

g h

ours

Every

2 y

ears

or

5000

opera

tin

g h

ours

Work Carried out by Date

Radial riveting machine RNE 181 HPP Decommissioning, Storage

803835.006/ENG 61

9 Decommissioning, Storage

9.1 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.

Disposal Radial riveting machine RNE 181 HPP

62 803835.006/ENG

10 Disposal

10.1 Introduction


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:

Lubricants

Hydraulic oils

Plastics

Batteries

Pressure accumulator (depressurize, empty)

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG 63

11 Appendix

11.1 Schemata

11.1.1 Pneumatic diagram with air maintenance unit 181 reduced force, 803541

Item Name

0.1 Air maintenance unit comprising filter regulator, lubricator, manometer

0.2 Air maintenance unit comprising filter regulator, lubricator, manometer and additional outlet

1.0 Riveting unit

1.01 Restrictor valve (advance speed setting)

1.02 Restrictor valve (return speed setting)

1.1 5/2-way valve

Appendix Radial riveting machine RNE 181 HPP

64 803835.006/ENG

11.1.2 Pneumatic diagram 181 reduced force with proportional pressure regulator 803584

Item Name

0.1 Air maintenance unit comprising filter regulator, lubricator, manometer

0.2 Air maintenance unit comprising filter regulator, lubricator, manometer and additional outlet

1.0 Riveting unit

1.01 Restrictor valve (advance speed setting)

1.02 Restrictor valve (return speed setting)

1.1 5/2-way valve

1.2 Proportional pressure regulator


803835.006/ENG 65

11.1.3 Pneumatic diagram for automatic lubrication 802417

Item Name

0.1 Pressure control valve

1.0 Grease container

1.1 Solenoid valve

2.0 Injection lubricator (metering valve)


66 803835.006/ENG

11.2 Spare parts lists

11.2.1 Machine body 181 reduced force Standard/HPP 825403-b


803835.006/ENG 67


68 803835.006/ENG

Pos. No. Part Name Part No. Remarks

1 1 Cast housing 825908 Standard

2 1 Cast housing 825912 Flange mounting

3 1 Damping piston 825909 Standard

4 1 Guide sleeve 823069

6 1 Cam 823195

7 1 Eccentric sleeve 825038

9 1 Flange 825035 Standard

10 1 Connecting piece 825067

11 1 Adjustment ring 825066

12 1 Adhesive label "BalTec" 825110

13 1 Cover tube 825073 Standard

14 1 Key 825036

15 1 Scale 823023

16 1 Internal ring gear 811035

17 1 Eccentric shaft 814018

18 1 Washer 825039

19 1 Key 390108

20 2 Buffer disc 823027

21 1 Motor flange 825910 Standard

22 2 Cylinder head screw 341012 In-6kt M4x16 DIN 912-12.9

23 1 Mounting nut 522545 E-8, M10x1

24 1 Cover tube 825183 Flange mounting

25 1 Pan head screw 346071 In-6kt M4x8 ISO 7380-10.9






31 1 Flange 825182 Flange mounting

32 1 Locking screw 838094

33 2 Axial ball bearing 330056 51106

34 2 Axial needle ring 330004 AXK 1528

35 2 Needle bearing 331252 NK 30/20

36 1 Counter sunk screw 342811 In-6kt M5x12 DIN 7991-10.9


803835.006/ENG 69


37 2 Needle ring 331024 K 14x18x13

38 1 I.D. Seal 360350 KSD – Ring

40 1 I.D. Seal 360352 KSD – Ring

41 1 O.D. Seal 360360 KSD – Ring

42 1 Damping sealing ring 361945 CYBU PEI 52x62 A01

43 1 Compensating washer 337003

44 1 Compensating washer 337005

45 1 O – Ring 362065 45 – 2.5 NBR 70 Shore

48 3 O – Ring 362125 96 – 2 NBR 70 Shore

49 1 Stop nut 348991 Nyloc M5 DIN 985

50 2 Restrictor valve 368613 AS2301F-01-06S

51 1 Clamping fixture complete 825074

54 2 Cable clamp 525305

55 2 Phillips pan head thread cutting screw

346680 Type 2 M3x8 BN 1023

56 1 Proximity switch 522517 M5 PNP/NO

57 1 Proximity switch holder 824053

58 2 Stopper 389911 3126 08 00

60 1 Proximity switch 522519 M8 PNP IFRM 08P1703/S35L

63 1 Stopper 371507 TL-4-093 for M10x1

64 1 Counter washer 330251 CP 1426

66 1 Dowel pin 356065 ø3x16 VSM 12785

67 6 Locking washer 351707 for M5

72 1 Plug with cable 522532 BKS-S 49-1-03

73 1 Motor flange 825911 HPP

76 1 Intermediate flange 826064 for USA-Motor


87 2 Shaft and housing locating washer 330702 LS 1528

98 2 Distributor 825088

99 2 Hollow-core screw 374192 G1/8" HI 118K

100 2 Screw plug 371427 R1/8" conical

104 2 Pressure transmitter 540392 0 – 10 bar

105 2 Connection cable to pressure transmitter

540393 L = 2m

1 Set of bearings 333411

1 Set of seals 363558


70 803835.006/ENG

11.2.2 Riveting head 081-241 814310-h

RNL/RNEL 231 mit NHE ohne Initiator UT RNL/RNEL 231 with NHE without initiator BDC

Autom. Schmierung Automatic lubrication


803835.006/ENG 71


1 1 Cap 814057 RN/RNE 081/181/231/241

2 2 Screw 341006 In-6kt M3x12 DIN 912-12.9

3 1 Pressure spring 820026

4 1 Cap 865899 RN/RNE 181/231 with NHE

5 1 Holder 865904

6 4 Screw 341083 In-6kt M4x25 DIN 912-12.9

7 2 O-Ring 362086 60-1,5

8 1 Form tool holder complete 814050 R= 65 / L= 39

9 1 Form tool holder complete 814051 R= 80 / L= 54

10 1 Form tool holder complete 814052 R=100 / L= 74

11 1 Form tool holder complete 814053 R=120 / L= 94

12 1 Form tool holder complete 814054 R=132 / L=106

13 1 Pressure cup 814001 R= 65 / L= 39

14 1 Pressure cup 814010 R= 80 / L= 54

15 1 Pressure cup 814012 R=100 / L= 74

16 1 Pressure cup 814014 R=120 / L= 94

17 1 Pressure cup 814016 R=132 / L=106

18 1 Lubricating nipple 319718

19 1 Ring fitting 366916

20 1 Hollow core screw 374179

21 2 Bonded seal 361108 USIT 5.7x9x1

22 1 Block 814151

23 2 Screw 341024 In-6kt M6x16 DIN 912-12.9

24 1 Oil hose 040034 PA Ø2.5/1.5 L = ca. 500mm

25 1 Cap 826092 RN ONLY Type 1

26 4 Screw 341011 In-6kt M4x12 DIN 912-12.9

27 4 Locking washer 351706 M4

28 2 Connection fitting 366913

29 1 Sealing ring 363681 DA M5

30 1 Cap 814164 RNL/RNEL 231/90

31 1 Cap (reworked) 814165 RNL/RNEL 231/90 with NHE

101 1 Spherical plain bearing to form tool holder

325802 GE 8 DO

102 1 Magnet to form tool holder 390001

103 1 Circlip to form tool holder 354510 SB 16


72 803835.006/ENG

11.2.3 Electric motor 181 825320-m

Pos. No. Part name Part no. Remarks

1 1 Spring dowel sleeve 355333 "PRYM" ø4x24 DIN 7343

2 1 Polygon shaft 825053 Standard

3 1 Electric motor 542860 3x230/400V 50Hz, 3x265/460V 60Hz

4 1 Electric motor 542861 3x575V 60Hz




8 1 Polygon shaft 825060 Bodine-Motor


10 1 Feed cable motor 520169

14 1 Cable fitting 525794 M20x1.5mm 5.5-12.0mm


16 1 Cover 826012

17 3 Pan head screw 359137 M4x8 eco-fix H BN 4825 4H

18 4 Cylinder head screw 341231 In-6kt 3/8"-16 UNC x 1"

19 2 Flat plug AMP 525107 6,3x0.8 IFH 1.5

20 1 Electric motor 542918 3000rpm

21 1 Polygon shaft 826035 STF with Bodine-Motor

22 1 Feed cable motor 520169.01 USA/Canada

23 1 Cover bracket 825167


803835.006/ENG 73

11.2.4 Pneumatics 181 STF/HPP 825328-n


74 803835.006/ENG


2 1 Bracket 814087

5 1 5/2-way valve 369345 1/4"

6 2 Silencer 379924 1/4"

7 1 Plastic hose 040038 ø12/8, L = 130mm

8 1 Direct joint 367712 1/4" ø12

9 2 Direct joint 367739 828-0406 (Standard)

9 2 Direct joint 367738 828-0404 (RNE reduced force)

10 2 Plastic hose 040021 PS 86 L=… (Standard)

10 2 Plastic hose 040026 PS 64 L=… (RNE reduced force)

11 2 Screw 341023 M6x12

12 1 Indicating label 250004

14 2 Screw 341626 M4x50

15 1 Direct joint 367713 3/8" ø12

16 1 Air maintenance unit 368300 3/8", 2-part

Single parts to Pos. 16 obtainable:

Filter-regulator 368307 C.12, 3/8"

Mist oiler 368327 L.12, G3/8"

Manometer 369812 Ø50, 0-10 bar

Gasket for manometer 363692 ¼“

Tank for filter 368312

Tank for lubricator 368313



Filter 368302 F.12, 3/8"

Mist oiler 368327 L.12, G3/8"

Distributor 4-part 368305 T.12, 3/8“

Pressure regulator 368303 R.12, 3/8“




Tank for lubricator 368313


803835.006/ENG 75


18 2 Screw 341507 M4x30

19 1 Plug socket black 369347 22mm 230-364A

20 1 Plug socket transparent 369348 22mm 230-392A (if NHE or path-measuring system)

21 2 Protecting cage 368311 optional

22 1 Cable to valve 520235 L = 1300mm

23 1 Filter-regulator 368301 C.12 G, 3/8“


Filter-regulator 368307 C.12






Filter 368302 F.12, 3/8"

Distributor 4-part 368305 T.12, 3/8“

Pressure regulator 368303 R.12, 3/8“





76 803835.006/ENG

11.2.5 Automatic lubrication 814340-u


803835.006/ENG 77


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


14.1 1 Clamping ring 366912 2.5x1.5 brass

14.2 1 Tube connection 366911 M8x1.00x3/32“



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



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


Lubricating grease (1kg can) 060309 Klübersynth GE 46-1200


78 803835.006/ENG

11.2.6 Foot switch 813345-d


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


803835.006/ENG 79

11.2.7 Two-hand operating unit 814350-d


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



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 HPP-25 L=1500

15 6 Pan head screw 346090 M3x6 ECO-FIX Form H, BN 4825 4.8

16 1 Supply cable 520661 HPP-25 L=2000 for RND, RNS, RNFS


80 803835.006/ENG

11.2.8 Pressure pad 081-241 814315-d


803835.006/ENG 81


1 1 Pressure piece Client specific

2 1 Cap 814058

3 1 Pressure spring 820026


5 2 O-Ring 362086 60-1.5

6 1 Straight pin 355068 3x10

7 1 Snap ring 354239 46x1.75

8 1 Form tool holder complete without O-Ring

814051 R=80 / L=54

8 1 Form tool holder complete with O-Ring

814146 R=80 / L=54


814052 R=100 / L=74


814147 R=100 / L=74

10 1 Pressure cup 814010 R=80 / L=54

11 1 Pressure cup 814012 R=100 / L=74

12 7 Spring washer 314075 45x22.4x1.25 (60 – 170 daN)



15 1 Lubricating nipple 319718

16 1 Banjo fitting 366916

17 1 Hollow-core screw 374179 H1 M5 K

18 4 Bonded seal 361108 USIT U 5.7-9-1


814053 R=120 / L=94


814148 R=120 / L=94


814054 R=132 / L=106


814149 R=132 / L=106

21 1 Pressure cup 814014 R=120 / L=94

22 1 Pressure cup 814016 R=132 / L=106

29 1 Aluminium sealing ring 363681 DA M5

30 1 Block 814151


33 1 Oil hose 040034 PA Ø2.5/1.5 L= ca. 500mm



82 803835.006/ENG

11.2.9 Path-measuring system HPP-181, 825408-c


803835.006/ENG 83


1 1 Sensor support 826133

2 1 Support 825284

3 1 Clamping ring 825285

4 1 Magnetic tape support 826104

5 1 Cover 825282

7 1 Magnetic field sensor 540421 MIL 10

8 1 Magnetic tape 540408 MLFK



12 2 Pan head screw 346080 M3x6


14 1 Mounting nut 522545 E-8, M10x1


with initiator TDC, Standard machines

15 1 Proximity switch 522519 M8 PNP

16 1 Angular plug connector with cable 522532 Cable L=3m

with initiator TDC, RNC

15 1 Proximity switch 522519 M8 PNP

19 1 Angular plug connector with cable 522546 Cable L=10m

without initiator TDC

17 1 Stopper 371504 Ø=7mm Type 6019 metrical


84 803835.006/ENG

11.2.10 Riveting stroke limit switch unit NHE-U 181-231, 825290.01


1 1 NHE basic unit 826098 181-381

2 1 Basic plate small 825292

3 1 Slide 825262

4 1 Turning lever 825265

5 1 Cover below 825289

6 1 Cover above 825299

7 1 Fitting bolt 341398 d6x20/ M5

8 1 Fitting bolt 341412 reworked

9 1 My-Com-Switch 522676 M75/S35

10 1 Cable 520644

11 1 Torsion spring 316637

12 1 Screw 341025 In-6kt M6x20

13 1 Washer large 348805 M6

14 1 Screw 341002 In-6kt M3x5

15 3 Screw 346078 In-6kt M4x6

16 2 Screw 346091 In-6kt M5x10

17 6 Screw 341018 In-6kt M5x16

18 2 Cylinder pin 355090 4-h6x16


803835.006/ENG 85

11.2.11 Riveting stroke limit switch unit NHE-H 181-231, 825290.03-a


1 1 NHE basic unit 826098 181-381




15 3 Pan head screw 346078 In-6kt M4x6




21 1 Distance plate 825298


23 1 Plate 825288

24 1 Magnetic tape 540409 MLFK L=25


26 2 Counter sunk screw 342801 In-6kt M3x6


86 803835.006/ENG

11.2.12 Riveting stroke limit switch unit NHE-E 181-231, 825290.07-a


1 1 NHE basic unit 826098 181-381

2 1 Basic plate small 826109 reworked

3 1 Slide 825262






9 1 My-Com-Switch 522676 RC-30 or HPP-25 control

10 1 Cable 520644


12 1 Screw 341025 In-6kt M6x20


14 1 Screw 341002 In-6kt M3x5

15 3 Screw 346078 In-6kt M4x6

16 2 Screw 346091 In-6kt M5x10

17 6 Screw 341018 In-6kt M5x16


55 1 Rotary knob 310730

56 1 Adjustment spindle 825294

57 1 Heavy duty dowel pin 356060 Ø3x8

58 1 Pressure spring 316632 0.8x8.0x32

67 1 Switching amplifier with housing 826120 LC-, RX- or external control

68 1 My-Com-Switch 522678 LC-, RX- or external control


803835.006/ENG 87

11.2.13 Riveting stroke limit switch unit NHE-Combi 181-231, 825290.09-a


1 1 NHE basic unit 826098 181-381


3 1 Slide 825262




9 1 My-Com-Switch 522676 M75/S35

10 1 Cable 520644









23 1 Plate 825288

24 1 Magnetic tape 540409 MLFK L=25


26 2 Counter sunk screw 342801 In-6kt M3x6






47 2 Cable clamp 525305 d=4.5



88 803835.006/ENG

11.2.14 Riveting stroke limit switch unit (NHE) basic unit 181 – 431, 826098


1 1 Guiding plate 825295

2 1 Support 825296

3 1 Slider 825293

4 1 Guiding slide 338053 MGN12H

5 1 Profile rail 338063 MGNR12 L=64

6 1 Fitting bolt 341399 d6x25/M5

7 1 Standard pressure spring 316622 1.25x10x64

8 1 Threaded pin 346980 In-6kt with flat point M14x14

9 1 Cylinder pin 355435 m6 d8x18

10 2 Cylinder pin 355087 h6 d4x10

11 4 Screw 341502 In-6kt M3x20

12 3 Screw 341006 In-6kt M3x12

13 2 Screw 341018 In-6kt M5x16


803835.006/ENG 89

11.2.15 Proportional pressure regulator 181/231/281 868191


1 1 Proportional pressure regulator 529518

2 1 Feed cable with connector 529519

3 2 Swivelling screw fit 367861 G 1/8“ Ø10

4 1 Silencer 379923 1/8“

5 1 Straight screw connection 367740 G1/4“, d10

6 1 Straight screw connection 367752 G3/8“, d10

7 2 Cylinder head screw 341629 In-6kt with shank M4x70

8 2 Plastic hose 040023 black Ø10/8


90 803835.006/ENG

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 Frankreich Schweden

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

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

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

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

Colly Company AB 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]

Australien Grossbritannien, Irland Schweiz

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

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

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

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

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

Baltik Indien Singapur

CLE Baltic Sära street 10 Peetri village Rae county 75312 Estonia

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

Francis Klein & Co. Private Ltd. 70/1, Mission Road IN-Bangalore - 560 027 India

Tel.: 0091 80 2227 2781 0091 80 2227 2782 Fax: 0091 80 2227 6324 [email protected]

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

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

BeNeLux Italien Slowakei

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

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

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

Brasilien Japan Slowenien, Kroatien

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

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

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

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

Bulgarien Kolumbien Spanien, Portugal

ALFLETH ENGINEERING AG Hardstrasse 4 CH-5600 Lenzburg Switzerland

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

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

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

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

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

Tel.: 0034 630 442 457 [email protected]

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

China Korea

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

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

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]

Dänemark Norwegen Südafrika

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

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

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

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

Deutschland PLZ: 6, 7, 8 (ausser 83), 90-94 Oesterreich, Deutschland PLZ: 83 Thailand

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

Tel: 0049 7335 923 412 Fax: 0049 7335 923 3069 Mobile: 0049 175 1816 132 [email protected]

HAMOTEK Montagetechnik GmbH Untersbergstrasse 1b AT-5082 Grödig Oesterreich

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

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

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

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

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

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

OK-Strojservis Polska Sp. z o.o ul. Technologiczna 2A PL-45-839 Opole Polska

Tel.: 0048 690 368 321 [email protected] www.ok-strojservis.pl

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

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

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

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

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

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

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

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

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

Finnland Russland Ungarn

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

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

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

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


803835.006/ENG 91

Index Radial riveting machine RNE 181 HPP

92 803835.006/ENG

12 Index

A

Air maintenance unit ................................................... 54

Application limitations ................................................... 9

Automatic lubrication riveting spindle head ........... 36, 53

B

Basic settings ............................................................. 19

C

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

D

Declaration of incorporation ........................................ 12

Declarations ................................................................ 12

Decommissioning ....................................................... 61

Dimensions drawing RNE 181 reduced force with path-measuring system HPP .......................................... 14

Dimensions drawing RNE 181 reduced force with path-measuring system HPP for flange mounting .......... 15

Dimensions drawing RNE 181-231 HPP with NHE .... 46

Disposal ...................................................................... 62

E

Electrical power supply ................................................. 9

Emissions ................................................................... 11

Environmental conditions .............................................. 9

F

Foot switch ................................................................. 37

Form tool D = 10 with various lengths ........................ 26

Form tool designs and closing head shapes ............... 24

G

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

H

Heating of riveting machine ........................................ 18

I

Information and symbols ............................................... 8

Initiator lower end position (bridging initiator) ............. 39

Initiator upper end position ......................................... 39

Intended use ............................................................... 10

M

Magnetic field sensor adjustment ............................... 43

Maintenance and repair log ........................................ 59

Maintenance work....................................................... 49

Mechanical power supply ............................................. 9

Mist oiler adjustment ................................................... 55

Modifications ............................................................... 12

My-Com Switch substitution ....................................... 42

N

Noise ........................................................................... 11

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

O

Oils recommended ...................................................... 55

Operator ........................................................................ 7

Original language of assembly instructions ................... 6

P

Personal safety equipment ......................................... 18

Personnel ...................................................................... 7

Personnel qualification .................................................. 7

Piston and piston rod seals ......................................... 57

Polygon shaft .............................................................. 56

Possible machine settings .......................................... 23

Power supply .............................................................. 11

Pressure pad............................................................... 32

Pressure pad dimensions drawing .............................. 33

Pressure/force diagram ............................................... 21

Product life phases ....................................................... 7

Production of thrust piece and spring diagram 802297 ............................................................................... 34

Proportional pressure regulator................................... 47

Q

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

R

Recommended form tool materials ............................. 25

Re-commissioning ...................................................... 61

Replaced parts ............................................................ 62

Replacing the form tool holder and pressure cup........ 27

Rivet parameters ........................................................... 9

Riveting force adjustment ........................................... 21

Riveting motor terminal box ........................................ 58

Riveting spindle........................................................... 51

Riveting spindle advance speed adjustment ............... 20

Riveting spindle head (form tool holder and pressure cup) ........................................................................ 50

Riveting spindle return speed adjustment ................... 20

Riveting stroke adjustment .......................................... 19

Riveting stroke limit switch unit NHE 181-231............. 40

Riveting to stroke limiting stop .................................... 23

Riveting under high pressure ...................................... 23

Riveting under low pressure ....................................... 23

Riveting without stroke limiting stop ............................ 23

RNE 181 reduced force HPP details ........................... 13

S

Schemata .................................................................... 63

Setting up the riveting machine for a new workpiece .. 22

Radial riveting machine RNE 181 HPP Index

803835.006/ENG 93

Significance of the safety regulations ........................... 7

Spare parts lists .......................................................... 66

Spring prestress adjustment riveting stroke limit switch unit NHE ................................................................. 45

Standard form tool Ø10 with conical profile (081-241) 30

Standard form tool Ø10 with crowned profile (081-241) ............................................................................... 31

Standard form tool Ø10 with flat profile (081-241) ...... 29

Storage ....................................................................... 61

T

Technical specifications riveting machine 181 reduced force max. 1.5 kN ................................................... 16

Topping up the grease container ................................ 53

Touch probe switching point NHE-E adjustment ......... 44

Two-hand operating unit ............................................. 57

U

User .............................................................................. 7

V

Vibrations .................................................................... 11

W

Warning and safety notices ........................................... 8

Workplace ................................................................... 18

Index Radial riveting machine RNE 181 HPP

94 803835.006/ENG

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Radial riveting machine RNE 181 HPP - baltecorporation.com · Radial riveting machine RNE 181 HPP Safety regulations 803835.006/ENG 7 2 Safety regulations 2.1 Term definitions The