radial riveting machine rne...

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

803858.011/ENG

OPERATING INSTRUCTIONS

Radial riveting machine

RNE 381

without Control

803858.011/ENG

Machine no. xxx.xxxx

Power supply xxx

Introduction Radial riveting machine RNE 381

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Radial riveting machine RNE 381 Introduction

803858.011/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 381 details ................................................................................................................................ 13

3.2 Hydraulic aggregate RNE 381 details ............................................................................................... 14

3.3 Dimensions drawing RNE 381 .......................................................................................................... 15

3.4 Dimensions drawing RNE 381 for flange mounting .......................................................................... 16

3.5 Technical specifications riveting machine 381 .................................................................................. 17

4 Commissioning ....................................................................................................... 18

4.1 Introduction........................................................................................................................................ 18 4.1.1 Personnel requirements ............................................................................................................... 18

4.2 Riveting unit ...................................................................................................................................... 18

5 Operation ................................................................................................................. 19

5.1 Safety regulations riveting machine .................................................................................................. 19 5.1.1 Personal safety equipment .......................................................................................................... 19 5.1.2 Workplace .................................................................................................................................... 19 5.1.3 Heating of riveting machine ......................................................................................................... 19 5.1.1 Heating of hydraulic aggregate .................................................................................................... 19

5.2 Basic settings .................................................................................................................................... 20 5.2.1 Riveting stroke adjustment ........................................................................................................... 20 5.2.2 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 = 20 with various lengths............................................................................................... 26

6.4 Replacing the form tool holder and pressure cup ............................................................................. 28

6.5 Replacing the pressure cup with the removal device ....................................................................... 30

6.6 Standard form tool Ø20 with flat profile (270-431) ............................................................................ 31

6.7 Standard form tool Ø20 with conical profile (270-431) ..................................................................... 32

6.8 Standard form tool Ø20 with crowned profile (270-431) ................................................................... 33


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7 Options .................................................................................................................... 34

7.1 Pressure pad .................................................................................................................................... 34 7.1.1 Pressure pad dimensions drawing .............................................................................................. 35 7.1.2 Production of thrust piece and spring diagram 802296 .............................................................. 36

7.2 Automatic lubrication riveting spindle head ...................................................................................... 38

7.3 Foot switch ....................................................................................................................................... 39 7.3.1 Function ....................................................................................................................................... 39 7.3.2 Dimensions drawing .................................................................................................................... 39 7.3.3 Technical specifications .............................................................................................................. 40

7.4 Initiator upper end position ............................................................................................................... 41

7.5 Initiator lower end position (bridging initiator) ................................................................................... 41

8 Maintenance and repair work ................................................................................ 42

8.1 Introduction ....................................................................................................................................... 42 8.1.1 Safety regulations ........................................................................................................................ 42 8.1.2 Personnel requirements .............................................................................................................. 42

8.2 Overview of maintenance work ........................................................................................................ 43 8.2.1 Riveting spindle head (form tool holder and pressure cup) ........................................................ 44 8.2.2 Riveting spindle ........................................................................................................................... 45 8.2.3 Automatic lubrication riveting spindle head (option) ................................................................... 47 8.2.4 Hydraulic aggregate .................................................................................................................... 48 8.2.5 Polygon shaft ............................................................................................................................... 50 8.2.6 Two-hand operating unit ............................................................................................................. 51 8.2.7 Piston and piston rod seals ......................................................................................................... 51 8.2.8 Riveting motor terminal box ........................................................................................................ 52

8.3 Maintenance and repair log .............................................................................................................. 53

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

9.1 Decommissioning ............................................................................................................................. 55

9.2 Storage ............................................................................................................................................. 55

9.3 Re-commissioning ............................................................................................................................ 55

10 Disposal ................................................................................................................... 56

10.1 Introduction ....................................................................................................................................... 56 10.1.1 Personnel requirements .............................................................................................................. 56

10.2 Disposal ............................................................................................................................................ 56 10.2.1 Replaced parts ............................................................................................................................ 56 10.2.2 Mineral oils .................................................................................................................................. 56 10.2.3 Riveting unit ................................................................................................................................. 56

11 Appendix ................................................................................................................. 57

11.1 Schemata ......................................................................................................................................... 57 11.1.1 Hydraulic diagram 381 801949-d ................................................................................................ 57 11.1.2 Pneumatic diagram for automatic lubrication 802417 ................................................................. 58

11.2 Spare parts lists ................................................................................................................................ 59 11.2.1 Machine body 381 Standard/HPP 852401-b .............................................................................. 59 11.2.2 Riveting head 270-431 838310-k ................................................................................................ 65 11.2.3 Electric motor 381 852320-k ....................................................................................................... 67 11.2.4 Automatic lubrication 814340-u ................................................................................................... 68 11.2.5 Foot switch 813345-d .................................................................................................................. 70 11.2.6 Two-hand operating unit 814350-d ............................................................................................. 71 11.2.7 Pressure pad 270-431 838315-g ................................................................................................ 72 11.2.8 Hydraulic aggregate RNE 381 852435-q .................................................................................... 74 11.2.9 Pressure transmitters fixing 852070-e ........................................................................................ 76

12 Index ........................................................................................................................ 79

Radial riveting machine RNE 381 Introduction

803858.011/ENG 5


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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 381 Safety regulations

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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 381

8 803858.011/ENG

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 381 Product description

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3 Product description

3.1 RNE 381 details

Item Name Item Name

1 Riveting stroke adjustment 6 Riveting spindle head

2 Clamping screw for riveting stroke adjustment

7 Form tool

3 Lubricator nipple 17 Initiator lower end position (option)

4 Hydraulic connection riveting spindle advance

21 Initiator upper end position (option)

5 Hydraulic connection riveting spindle return

Product description Radial riveting machine RNE 381

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3.2 Hydraulic aggregate RNE 381 details

Item Name Item Name

1 Electric motor 7 Return line filter with aerating filter

2 Intermediate flange 8 Magnetic valve

3 Oil tank 9 Pressure regulator valve (pressure limit cartridge)

4 Oil filler 11 Oil level indicator

5 Manometer 12 Connecting thread R 3/8“

6 Valve manifold


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3.3 Dimensions drawing RNE 381

Drawing no. 852400.30

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

Product description Radial riveting machine RNE 381

16 803858.011/ENG

3.4 Dimensions drawing RNE 381 for flange mounting

Drawing no. 852400.34

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


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3.5 Technical specifications riveting machine 381

Maximum rivet shaft diameter (solid shaft rivet, steel 370 N/mm2)

Ø 20

Riveting unit motor, driving power at 50Hz kW 1.1

Riveting unit motor, driving power at 60Hz kW 1.1

Riveting unit motor, rpm at 50Hz min-1 1390

Riveting unit motor, rpm at 60Hz min-1 1660

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

kW 1.1

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

kW 1.27

Rated current riveting unit motor at 3 x 220V A 6.5



Rated current hydraulic aggregate motor A 2.7

Hydraulics operating pressure bar 10 - 65

Max. output hydraulic pump at 50Hz l/min 8.7

Max. output hydraulic pump at 60Hz l/min 10.4

Max. riveting force kN 40

Max. permissible riveting time per cycle sec 10

Tool stroke (stroke limiting stop-adjustment range) mm 5 - 50

Weight of riveting machine without control unit kg 200

Weight of riveting machine with control unit kg 210

Weight of riveting unit kg 80

Weight of hydraulic aggregate empty kg 54

Commissioning Radial riveting machine RNE 381

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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.

Radial riveting machine RNE 381 Operation

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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!

5.1.1 Heating of hydraulic aggregate

Parts on the hydraulic aggregate heat during operation.

CAUTION

Heated parts on hydraulic aggregate!

Light burns!

Do not touch with unprotected hand!

Operation Radial riveting machine RNE 381

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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 force adjustment

The riveting force (operating pressure) is adjusted at the pressure regulator valve on the housing that is mounted under the control-box support or at the pressure regulator valve of the hydraulic aggregate.

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

Pressure/Force diagram

0

10

20

30

40

50

60

70

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

F [kN]

P [bar]

P = operating pressure F = riveting force

NOTICE

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

Operation Radial riveting machine RNE 381

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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 381

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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 381 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 = 20 with various lengths

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

Procedure:

1. Form tool in installed condition

2. Undoing the form tool:

• Insert removal device in groove

• Lever removal device upwards until the form tool loosens

3. Pull form tool downwards

CAUTION

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


803858.011/ENG 27

Item Name

1 Form tool axis

2 Pressure cup

3 Form tool holder

4 3 thrust pieces

5 Form tool

Machines Type

Radius Rp [mm]

Form tool length

Ls [mm ± 0.1]

Shaft Ds [mm]

Angle

Free height H

[mm]

270 281 331 381

100 68

20g6

5° 37´ 28

116 84 4° 47´ 44

132 100 4° 10´ 60

148 116 3° 41´ 76


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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!


803858.011/ENG 29

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 M5x70 provided in the machine accessories and insert a new pressure cup

CAUTION

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

5. 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


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6.5 Replacing the pressure cup with the removal device

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

Item Name

1 Removal device

2 Internal ring gear

3 Pressure cup

4 Special screws M5x120

5 Connection piece

CAUTION

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


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

Ls = 68 ± 0.1 Ls = 84 ± 0.1 Ls = 100 ± 0.1

Article-no.

Øds ± 0.1

α° L2 L3 Article-

no. Øds ± 0.1

α° L2 L3 Article-

no. Øds ± 0.1

α° L2 L3

883121** 2.0 25-45 883127 2.0 25-45 883133 2.0 25-45

883122 2.5 25-45 883128 2.5 25-45 883134 2.5 25-45

883123** 3.0 25-45 883129 3.0 25-45 883135 3.0 25-45

883124 3.5 25-45 883130 3.5 25-45 883136 3.5 25-45

883125** 4.0 25-45 883131 4.0 25-45 883137 4.0 25-45

883126 4.5 25-45 883132 4.5 25-45 883138 4.5 25-45

883001* 5.0 15-45 883042 5.0 15-45 883081 5.0 15-45

883002 5.5 15-45 883043 5.5 15-45 883082 5.5 15-45

883003* 6.0 15-45 883044 6.0 15-45 883083 6.0 15-45

883004 6.5 15-45 883045 6.5 15-45 883084 6.5 15-45

883005* 7.0 15-45 883046 7.0 15-45 883085 7.0 15-45

883006 7.5 15-45 883047 7.5 15-45 883086 7.5 15-45

883007* 8.0 15-45 883048 8.0 15-45 883087 8.0 15-45

883008 8.5 15-45 883049 8.5 15-45 883088 8.5 15-45

883009* 9.0 15-45 883050 9.0 15-45 883089 9.0 15-45

883010 9.5 15-45 883051 9.5 15-45 883090 9.5 15-45

883011* 10.0 15-45 883052 10.0 15-45 883091 10.0 15-45

883012 10.5 15-45 883053 10.5 15-45 883092 10.5 15-45

883013* 11.0 15-45 883054 11.0 15-45 883093 11.0 15-45

883014 11.5 15-45 883055 11.5 15-45 883094 11.5 15-45

883015* 12.0 15-45 883056 12.0 15-45 883095 12.0 15-45

883016 12.5 15-45 883057 12.5 15-45 883096 12.5 15-45

883017* 13.0 15-45 883058 13.0 15-45 883097 13.0 15-45

883018 13.5 15-45 883059 13.5 15-45 883098 13.5 15-45

883019* 14.0 15-45 883060 14.0 15-45 883099 14.0 15-45

883020 14.5 15-45 883061 14.5 15-45 883100 14.5 15-45

883021* 15.0 15-45 883062 15.0 15-45 883101 15.0 15-45

883022 15.5 15-45 883063 15.5 15-45 883102 15.5 15-45

883023* 16.0 15-45 883064 16.0 15-45 883103 16.0 15-45

883024 16.5 15-45 883065 16.5 15-45

883025* 17.0 15-45 883066 17.0 15-45

883026 17.5 15-45 883067 17.5 15-45

883027* 18.0 15-45 883068 18.0 15-45

883028 18.5 15-45 883069 18.5 15-45

883029* 19.0 15-45 883070 19.0 15-45

883030 19.5 15-45 883071 19.5 15-45

883031* 20.0 883072 20.0

883032 20.5 39 42

* = available from stock (α = 15°)

** = available from stock (α = 25°)

883033* 21.0 39 42

883034 21.5 39 42

883035* 22.0 39 42

883036 22.5 39 42

883037* 23.0 39 42

883038 23.5 39 42

883039* 24.0 39 42

883040 24.5 39 42

883041* 25.0 39 42


32 803858.011/ENG

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

Ls = 68 ± 0.1 Ls = 84 ± 0.1 Ls = 100 ± 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

884121** 2.0 25-45 5 5.7 884127 2.0 25-45 4.5 6.4 884133 2.0 25-45 4 7.2

884122 2.5 25-45 5 7.2 884128 2.5 25-45 4.5 8.0 884134 2.5 25-45 4 9.0

884123** 3.0 25-45 5 8.6 884129 3.0 25-45 4.5 9.6 884135 3.0 25-45 4 10.8

884124 3.5 25-45 5 10.0 884130 3.5 25-45 4.5 11.2 884136 3.5 25-45 4 12.5

884125** 4.0 25-45 5 11.5 884131 4.0 25-45 4.5 12.7 884137 4.0 25-45 4 14.3

884126 4.5 25-45 5 12.9 884132 4.5 25-45 4.5 14.3 884138 4.5 25-45 4 16.1

884001* 5.0 15-45 5 14.3 884042 5.0 15-45 4.5 15.9 884081 5.0 15-45 4 17.9

884002 5.5 15-45 5 15.8 884043 5.5 15-45 4.5 17.5 884082 5.5 15-45 4 19.7

884003* 6.0 15-45 5 17.2 884044 6.0 15-45 4.5 19.1 884083 6.0 15-45 4 21.5

884004 6.5 15-45 5 18.6 884045 6.5 15-45 4.5 20.7 884084 6.5 15-45 4 23.3

884005* 7.0 15-45 5 20.1 884046 7.0 15-45 4.5 22.3 884085 7.0 15-45 4 25.1

884006 7.5 15-45 5 21.5 884047 7.5 15-45 4.5 23.9 884086 7.5 15-45 4 26.9

884007* 8.0 15-45 5 22.9 884048 8.0 15-45 4.5 25.5 884087 8.0 15-45 4 28.7

884008 8.5 15-45 5 24.4 884049 8.5 15-45 4.5 27.1 884088 8.5 15-45 4 30.5

884009* 9.0 15-45 5 25.8 884050 9.0 15-45 4.5 28.7 884089 9.0 15-45 4 32.3

884010 9.5 15-45 5 27.3 884051 9.5 15-45 4.5 30.3 884090 9.5 15-45 4 34.0

884011* 10.0 15-45 5 28.7 884052 10.0 15-45 4.5 31.9 884091 10.0 15-45 4 35.8

884012 10.5 15-45 5 30.1 884053 10.5 15-45 4.5 33.5 884092 10.5 15-45 4 37.6

884013* 11.0 15-45 5 31.6 884054 11.0 15-45 4.5 35.1 884093 11.0 15-45 4 39.4

884014 11.5 15-45 5 33.0 884055 11.5 15-45 4.5 36.6 884094 11.5 15-45 4 41.2

884015* 12.0 15-45 5 34.4 884056 12.0 15-45 4.5 38.2 884095 12.0 15-45 4 43.0

884016 12.5 15-45 5 35.9 884057 12.5 15-45 4.5 39.8 884096 12.5 15-45 4 44.8

884017* 13.0 15-45 5 37.3 884058 13.0 15-45 4.5 41.4 884097 13.0 15-45 4 46.6

884018 13.5 15-45 5 38.7 884059 13.5 15-45 4.5 43.0 884098 13.5 15-45 4 48.4

884019* 14.0 15-45 5 40.2 884060 14.0 15-45 4.5 44.6 884099 14.0 15-45 4 50.2

884020 14.5 15-45 5 41.6 884061 14.5 15-45 4.5 46.2 884100 14.5 15-45 4 52.0

884021* 15.0 15-45 5 43.0 884062 15.0 15-45 4.5 47.8 884101 15.0 15-45 4 53.8

884022 15.5 15-45 5 44.5 884063 15.5 15-45 4.5 49.4 884102 15.5 15-45 4 55.6

884023* 16.0 15-45 5 45.9 884064 16.0 15-45 4.5 51.0 884103 16.0 15-45 4 57.3

884024 16.5 15-45 5 47.3 884065 16.5 15-45 4.5 52.6

884025* 17.0 15-45 5 48.8 884066 17.0 15-45 4.5 54.2

884026 17.5 15-45 5 50.2 884067 17.5 15-45 4.5 55.8

884027* 18.0 15-45 5 51.6 884068 18.0 15-45 4.5 57.4

884028 18.5 15-45 5 53.1 884069 18.5 15-45 4.5 58.9

884029* 19.0 15-45 5 54.5 884070 19.0 15-45 4.5 60.5

884030 19.5 15-45 5 55.9 884071 19.5 15-45 4.5 62.1

884031* 20.0 5 57.4 884072 20.0 4.5 63.7

884032 20.5 5 58.8 39 42

* = available from stock (α = 15°)

** = available from stock (α = 25°)

884033* 21.0 5 60.2 39 42

884034 21.5 5 61.7 39 42

884035* 22.0 5 63.1 39 42

884036 22.5 5 64.5 39 42

884037* 23.0 5 66.0 39 42

884038 23.5 5 67.4 39 42

884039* 24.0 5 68.8 39 42

884040 24.5 5 70.3 39 42

884041* 25.0 5 71.7 39 42


803858.011/ENG 33

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

Ls = 68 ± 0.1 Ls = 84 ± 0.1 Ls = 100 ± 0.1

Article no.

Øds

± 0.1 α° Ro

± 0.1

Bt

± 0.05 L2 L3

Article no.

Øds

± 0.1 α° Ro

± 0.1

Bt

± 0.05 L2 L3

Article no.

Øds

± 0.1 α° Ro

± 0.1

Bt

± 0.05 L2 L3

885121+ 2.0 25-45 3.3 0.10 885127 2.0 25-45 2.8 0.19 885133 2.0 25-45 3.2 0.16

885122 2.5 25-45 3.0 0.27 885128 2.5 25-45 3.5 0.23 885134 2.5 25-45 4.0 0.20

885123+ 3.0 25-45 4.8 0.18 885129 3.0 25-45 4.2 0.28 885135 3.0 25-45 4.8 0.24

885124 3.5 25-45 4.3 0.38 885130 3.5 25-45 5.0 0.32 885136 3.5 25-45 5.0 0.25

885125+ 4.0 25-45 6.6 0.25 885131 4.0 25-45 5.7 0.36 885137 4.0 25-45 5.8 0.29

885126 4.5 25-45 5.5 0.48 885132 4.5 25-45 6.4 0.41 885138 4.5 25-45 7.3 0.35

885001* 5.0 15-45 5.7 0.47 885042 5.0 15-45 7.2 0.45 885081 5.0 15-45 8.2 0.39

885002 5.5 15-45 6.3 0.52 885043 5.5 15-45 8.0 0.49 885082 5.5 15-45 9.1 0.43

885003* 6.0 15-45 7.0 0.57 885044 6.0 15-45 8.7 0.53 885083 6.0 15-45 10.0 0.46

885004 6.5 15-45 7.8 0.60 885045 6.5 15-45 9.5 0.57 885084 6.5 15-45 10.8 0.50

885005* 7.0 15-45 8.5 0.65 885046 7.0 15-45 10.3 0.61 885085 7.0 15-45 11.7 0.53

885006 7.5 15-45 9.0 0.71 885047 7.5 15-45 11.1 0.65 885086 7.5 15-45 12.7 0.57

885007* 8.0 15-45 9.8 0.75 885048 8.0 15-45 11.9 0.69 885087 8.0 15-45 13.6 0.60

885008 8.5 15-45 10.5 0.80 885049 8.5 15-45 12.7 0.73 885088 8.5 15-45 14.5 0.64

885009* 9.0 15-45 11.2 0.84 885050 9.0 15-45 12.8 0.73 885089 9.0 15-45 15.5 0.67

885010 9.5 15-45 12.0 0.88 885051 9.5 15-45 14.4 0.81 885090 9.5 15-45 16.4 0.70

885011* 10.0 15-45 12.6 0.93 885052 10.0 15-45 14.8 0.79 885091 10.0 15-45 17.4 0.73

885012 10.5 15-45 13.4 0.97 885053 10.5 15-45 16.1 0.88 885092 10.5 15-45 18.4 0.77

885013* 11.0 15-45 14.2 1.01 885054 11.0 15-45 17.0 0.92 885093 11.0 15-45 19.4 0.80

885014 11.5 15-45 15.0 1.05 885055 11.5 15-45 17.8 0.95 885094 11.5 15-45 20.4 0.83

885015* 12.0 15-45 15.7 1.10 885056 12.0 15-45 18.3 0.93 885095 12.0 15-45 21.4 0.86

885016 12.5 15-45 16.5 1.13 885057 12.5 15-45 19.6 1.02 885096 12.5 15-45 22.4 0.89

885017* 13.0 15-45 17.3 1.17 885058 13.0 15-45 20.5 1.06 885097 13.0 15-45 23.5 0.92

885018 13.5 15-45 18.0 1.22 885059 13.5 15-45 21.5 1.09 885098 13.5 15-45 24.5 0.95

885019* 14.0 15-45 18.9 1.25 885060 14.0 15-45 22.4 1.12 885099 14.0 15-45 25.6 0.97

885020 14.5 15-45 19.7 1.29 885061 14.5 15-45 23.4 1.15 885100 14.5 15-45 26.7 1.00

885021* 15.0 15-45 20.5 1.33 885062 15.0 15-45 24.3 1.19 885101 15.0 15-45 27.8 1.03

885022 15.5 15-45 21.5 1.36 885063 15.5 15-45 25.3 1.22 885102 15.5 15-45 28.9 1.06

885023* 16.0 15-45 22.3 1.39 885064 16.0 15-45 26.3 1.25 885103 16.0 15-45 29.8 1.03

885024 16.5 15-45 23.1 1.43 885065 16.5 15-45 27.3 1.28 885104 16.5 15-45 31.2 1.11

885025* 17.0 15-45 24.0 1.47 885066 17.0 15-45 28.3 1.31 885105 17.0 15-45 32.4 1.14

885026 17.5 15-45 25.0 1.49 885067 17.5 15-45 29.3 1.34 885106 17.5 15-45 33.6 1.16

885027* 18.0 15-45 25.8 1.53 885068 18.0 15-45 30.4 1.36 885107 18.0 15-45 34.8 1.19

885028 18.5 15-45 26.8 1.56 885069 18.5 15-45 31.4 1.39 885108 18.5 15-45 36.0 1.21

885029* 19.0 15-45 27.6 1.60 885070 19.0 15-45 32.5 1.42 885109 19.0 15-45 37.2 1.23

885030 19.5 15-45 28.6 1.63 885071 19.5 15-45 33.6 1.45 885110 19.5 15-45 38.5 1.26

885031* 20.0 29.4 1.65 885072 20.0 34.7 1.47 885111 20.0 39.2 1.22

885032 20.5 30.4 1.68 39 42

CAUTION 885033* 21.0 31.5 1.70 39 42

885034 21.5 32.4 1.73 39 42

885035* 22.0 33.5 1.76 39 42

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!

885036 22.5 34.5 1.79 39 42

885037* 23.0 35.5 1.82 39 42

885038 23.5 36.6 1.84 39 42

885039* 24.0 37.6 1.87 39 42

885040 24.5 38.8 1.89 39 42

885041* 25.0 39.8 1.92 39 42

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

Options Radial riveting machine RNE 381

34 803858.011/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 381 Options

803858.011/ENG 35

7.1.1 Pressure pad dimensions drawing

Machine type

081 151/170/181 220/231 241 270/281 331 381/431

A max. 30 max. 30 max. 30 max. 30 max. 62 max. 62 max. 62

B 55 55 55 55 90 90 90

C 75 75 75 75 125 125 125

D 7.5 (R80)

27.5 (R100)

7.5 (R80)

27.5 (R100)

7.5 (R80)

27.5 (R100)

7.5 (R80)

27.5 (R100)

4 (R116)

20 (R132)

36 (R148)

4 (R116)

20 (R132)

36 (R148)

4 (R116)

20 (R132)

36 (R148)

E 32 32 32 32 48 48 48

b 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”


36 803858.011/ENG

7.1.2 Production of thrust piece and spring diagram 802296

Spring diagram

F (daN) spring force Fmax. 2910 daN

Fmax. 1285 daN

Fmax. 670 daN

f (mm) travel

* Travel f = 0.75h do not exceed if possible

I 6 disk springs 80x41x2.25 (simple)

II 6 disk springs 80x41x3 (simple)

III 5 disk springs 80x41x4 (simple)


803858.011/ENG 37

Example: a and b sought for pre-stress force

Fv = 470 daN for I

Fv = 380 daN for II

Fv = 1250 daN for III

Spring combination Force at 0.75h

I a = 12

A travel of 7 (until f = 0.75h) remains for b -> F 660 daN

II a = 8

A travel of 7.4 (until f = 0.75h) remains for b -> F 1050 daN

III a = 10

A travel of 4.1 (until f = 0.75h) remains for b -> F 2250 daN

Thrust piece production

Material thrust piece: Case-hardened steel

Ra = 3.2

b = depends on application

Case-hardened 0.3...0.5 – 660 ± 20 HV10


38 803858.011/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. 6mm3 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. 1mm3.

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".


803858.011/ENG 39

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


40 803858.011/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 106

Ambient temperature, min..max. 30°C/+80°C

22°F/+176°F

30°C/+80°C

22°F/+176°F

Approvals CSA, UL CSA, UL, BG

Cable entry 1 x M20 x 1.5 3 x M20 x 1.5

Weight 1.5kg / 3.3lb 1.6kg / 3.5lb


803858.011/ENG 41

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.

Maintenance and repair work Radial riveting machine RNE 381

42 803858.011/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 381 Maintenance and repair work

803858.011/ENG 43

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

Hydraulic aggregate X X X

Filter Hydraulic aggregat

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


44 803858.011/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


803858.011/ENG 45

8.2.2 Riveting spindle


46 803858.011/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

8 Eccentric sleeve X

9 Eccentric shaft X X X

10 Internal ring gear X X X

25 Needle ring X X

37 Axial ball bearing X X

38 Needle bearing X X

39 Needle ring X X

40 Washer X

44 Lip seal X X

46 O.D. seal X X

47 Lip seal X X

48 O-Ring X X

49 Compensating washer X X

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

50 O-Ring X X

52 Thrust disk X

53 Thrust disk X

54 Compensating washer X X

55 Axial needle ring X X

56 Casing washer 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)!


803858.011/ENG 47

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


48 803858.011/ENG

8.2.4 Hydraulic aggregate

Filter

The hydraulic aggregate is furnished with a filter. Filtration: 10 Microns

The filter must be checked at least once a year or after 1000 operating hours. If necessary the aerating filter needs to be cleaned and the filter cartridge needs to be replaced.

Hydraulic oil

Under normal use, the hydraulic oil should be replaced approximately every 2 years or after 5'000 operating hours. At the same time, the aerating filter needs to be cleaned and the filter cartridge needs to be replaced.

CAUTION

Leakage of hot hydraulic oil!

Light burns!

Drain hoses before a maintenance!

Recommended oils

Type

Temperature range

+10 up to +55ºC +20 up to +65ºC

Quality

ISO-VG 32 (32 mm2/s) at 40ºC ISO-VG 46 (46 mm2/s) at 40ºC

BP BP Energol HLP 32, BP Energol HLP-D 32

BP Energol HLP 46, BP Energol HLP-D 46

ESSO NUTO H 32 NUTO H 46

MOBIL Mobil D.T.E. 24 Mobil D.T.E. 25

SHELL SHELL Tellus Oil 32 SHELL Tellus Oil 46

CASTROL CASTROL HYSPIN AWS 32 CASTROL HYSPIN AWS 46


803858.011/ENG 49

Filling of hydraulic oil

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

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

NOTICE

Fill the oil tank with filtered hydraulic oil only!

Ensure that there is no hydraulic oil spilled during the filling (hydraulic oil may not spill into the environment)!

Oil tank capacity

Series 241 (without rapid speed/working speed)

Series 381 Series 431

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

ca. 15 L ca. 24 L ca. 61 L

Hydraulic hose lines

The hydraulic hose lines have to be checked regularly for leak tightness or damage and replaced if necessary!

Motor terminal box

The motor terminal box of hydraulic aggregate has to be always closed during the operation. The terminal box can be opened for maintenance or fault finding.

DANGER

Touching of live parts on the open terminal box!

Electric shock!

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


50 803858.011/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.


803858.011/ENG 51

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).


52 803858.011/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!


803858.011/ENG 53

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


54 803858.011/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 381 Decommissioning, Storage

803858.011/ENG 55

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 381

56 803858.011/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 381 Appendix

803858.011/ENG 57

11 Appendix

11.1 Schemata

11.1.1 Hydraulic diagram 381 801949-d

GRIBI diagram no. A1212-2049

Pos. Name Pos. Name

1 Geared pump 9 Tank cover

2 Connecting flange 10 Return line filter with aerating filter

3 Connecting flange 11 Valve manifold

4 Intermediate flange 12 Glycerine manometer

5 Coupling 13 Pressure limit cartridge

6 Electric motor 14 4/3-port directional control valve

7 Oil tank 15 Non-return valve sandwich

8 Oil level indicator 16 Non-return valve

Appendix Radial riveting machine RNE 381

58 803858.011/ENG

11.1.2 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)


803858.011/ENG 59

11.2 Spare parts lists

11.2.1 Machine body 381 Standard/HPP 852401-b


60 803858.011/ENG


803858.011/ENG 61


62 803858.011/ENG

Pos. No. Part name Part no. Remarks

1 1 Cast housing 852093

2 1 Motor flange 852095 Standard

3 1 Flange below 852005 Standard

4 1 Upper piston 852094

5 1 Lower piston 852008

6 1 Cam 852054

7 1 Key 390108

8 1 Eccentric sleeve 852002

9 1 Eccentric shaft 838014

10 1 Internal ring gear 842053

11 1 Connection piece 853007

12 1 Key 842016

13 1 Scale 842014

14 1 Adjustment ring 852030

15 1 Motor flange 852096 HPP

16 1 Cover tube 852040 Standard

17 1 Washer 852000

18 1 Flange below 852063 for flange mounting

19 1 Cover tube 852064 for flange mounting

20 1 Distance tube 835250

21 1 Adhesive label "BalTec" 825110

24 1 Fixing nut 522545 E-8, M10x1

25 1 Needle ring 331049 K 20x28x25

26 8 Screw 341928 In-6kt low head M10x20 DIN 7984-8.8

27 8 Screw 341040 In-6kt M10x30 DIN 912-12.9

28 8 Locking washer 351710 for M10

29 3 Screw 342806 M4x10

30 2 Screw 341009 In-6kt M4x8 DIN 912-12.9


32 4 Screw 341520 In-6kt M6x35 DIN 912-12.9

33 1 Locking screw 838094

34 1 Dowel pin 356108 ø4x16 VSM 12785



803858.011/ENG 63


37 2 Axial ball bearing 330059 51109

38 2 Needle bearing 331267 NK 45/20

39 1 Needle ring 331048 K 20x24x17

40 1 Washer 330704 LS 2035

43 1 Stop nut 348993 Nyloc M8

44 1 Lip seal 362778 HALLITE Type 616, LI Ø45x56x3,9mm

45 1 Proximity switch 522665 M8x1 PNP/NO BES 516-324-SA33

46 1 O.D. seal 362431 NTH – Ring K 100238

47 1 Lip seal 362779 HALLITE Type 616, LI Ø75x90.5x6mm

48 2 O-Ring 362121 94 – 3 NBR 70 Shore

49 1 Compensating washer 337006 L&M 51/61x0.5

50 1 O-Ring 362082 59.5 – 3 NBR 70 Shore

52 1 Thrust disk 842189

53 1 Thrust disk 842190

54 1 Compensating washer 337007 L&M 28/34.5x0.5

55 2 Axial needle ring 330005 AXK 2035

56 2 Casing washer 330182 GS 81104 (ø20/35)

57 2 Cable clamp 525305

58 2 Screw 346748 M3x8 DIN 7500 C

59 1 Proximity switch 522517 M5 PNP/NO

60 1 Proximity switch holder 824053

62 2 Stopper 371513 TL-4-193

63 1 Stopper 371507 TL-4-093 for M10x1

65 1 Clamping fixture complete 853050

70 1 Angle connector with cable 522532 BKS-S 49-1-03

1 Set of bearings 333412

1 Set of seals 363566


64 803858.011/ENG


RNE without pressure monitoring

85 2 Pipe fitting straight 366085 GE 15-PLR-ED

RN without pressure monitoring


91 2 Tube 842092

92 2 Union nut 374917 M 15-L

93 2 Cutting ring 367815 DPR 15-L

RN/RNE/RNS with pressure monitoring

80 2 Adjustable angle connection piece 367514 EVL 15 PL

81 2 Reducing fitting 367812 KOR 5/10 PL

82 2 Tube 852050

83 2 Adjustable threaded elbow joint 374417 EVW 10 PL

84 2 Manometer fitting 369854 MAVE 10 LR


90 1 Pressure transmitters fixing 852070

RNS without pressure monitoring


94 2 Angle connection piece 374419 EVW 15-PL

RND without pressure monitoring

95 1 Swivelling fitting 366910 WH15LRKDSCF

96 1 Elbow connection piece 367541 EW15LREDCF


803858.011/ENG 65

11.2.2 Riveting head 270-431 838310-k

Pos. No. Part Name Part No. Remarks

1 1 Cap 838004 RN/RNE 281-431 Standard/HPP RNL/RNEL 281-331 Standard

5 4 Screw 341011 In-6kt M4x12 DIN 912-12.9

6 1 Pressure spring 840139 to form tool holder R = 100-148

7 2 O-Ring 362129 100-2


66 803858.011/ENG


8 1 Form tool holder complete 838050 R = 100 / L = 68




12 1 Pressure cup 838058 R = 100 / L = 68

13 1 Pressure cup 838059 R = 116 / L = 84

14 1 Pressure cup 838060 R = 132 / L = 100

15 1 Pressure cup 838061 R = 148 / L = 116

16 1 Lubricating nipple 319718

17 1 Ring fitting 366916

18 1 Hollow core screw 374179 H1 M5 K

19 2 Bonded seal 361108 USIT 5.7x9x1


21 1 Pressure cup 838084 R = 170 / L = 138


23 1 Pressure cup 838062 R = 191 / L = 159


25 1 Pressure cup 838086 R = 240 / L = 208

26 1 Pressure spring 836028 to form tool holder R = >148

27 1 Cap 838176 RNL/RNEL 281-331 HPP

28 1 Cap 865855 RN/RNE 281-431 NHE RNL/RNEL 281-331 NHE

29 1 Cap 846006 RNL/RNEL 381 Standard/HPP/NHE

30 1 Block 814151

31 2 Screw 341024 In-6kt M6x16 DIN 912-12.9

32 1 Oil hose 040034 PA Ø2.5/1.5 L = ca. 500mm

33 2 Connection fitting 366913

35 1 Cap (reworked) 868724 RN/RNE 281-431 with NHE hold-down force 236N

101 1 Spherical plain bearing to form tool holder

325805 GE 15 DO

102 1 Circlip to form tool holder 354517 SB26

103 3 Spring-loaded thrust pad to form tool holder

349891 GN 615-M4-K

1 Swivelling screw-fitting to lubricator „perma STAR CONTROL“

366151 M5x0.8d D=6


803858.011/ENG 67

11.2.3 Electric motor 381 852320-k


1 1 Spring dowel sleeve 355401 PRYM ø5x35 ISO 8748

2 1 Feed cable motor 520169

3 1 Electric motor 542854 3x230/400/415V 50Hz 3x230/460V 60Hz

4 1 Polygon shaft 852055

5 4 Cylinder head screw 341530 In-6kt M8x35 DIN 912-12.9

6 1 Electric motor 542855 3x575V 60Hz

7 1 Electric motor USA

8 1 Polygon shaft 852056 USA

12 1 Cable fitting 525794 M20x1.5 5.5-12.0mm

14 1 Cover 842213

15 1 Electric motor 542908 3x200V 50Hz

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

18 1 Cover bracket 853080

22 1 Feed cable motor 520169.01 USA/Canada


68 803858.011/ENG

11.2.4 Automatic lubrication 814340-u


803858.011/ENG 69


1 1 Grease container 814112

2 1 Pressure regulating unit 368325 DR.022-L378

12 1 Plug socket 369347 black 22mm 230-364 A

14 1 Injection lubricator 378008 L11 R 1/8“ KY 2033

Single parts to Pos. 14 obtainable:

14.1 1 Clamping ring 366912 2.5x1.5 brass

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


Single parts to Pos. 15 obtainable:

15.1 1 Clamping ring 366912 2.5x1.5 brass

18 1 Swivelling fitting 366150 1/8“, D=4 Art.-Nr. 0118 04 10

19 3 Screw plug 371012 B 18 23-02

21 1 Swivelling fitting 367744 1/8" 834-0204 K

23 1 Swivelling fitting 367746 1/4" 834-0404 K

25 1 Plastic hose 040026 PS 64

26 1 Plastic hose 040037 PA ø4/2.7

27 1 Oil hose 040034 PA ø2.5/1.5

28 2 Cylinder head screw 341015 In-6kt M5x8



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


70 803858.011/ENG

11.2.5 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


803858.011/ENG 71

11.2.6 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 RC-30/HPP-25, L=1500

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

16 1 Supply cable 520661 RC-30/HPP-25, L=2000


72 803858.011/ENG

11.2.7 Pressure pad 270-431 838315-g


803858.011/ENG 73


1 1 Pressure piece client specific

2 1 Cap 838016 RN/RNE 281-431

3 1 Pressure spring 840139


5 2 O-Ring 362129 100-2

6 1 Straight pin 355069 ø3h6x12 DIN 6325

7 1 Snap ring 354264 In 82x2.5 DIN 472




11 1 Pressure cup 838059 R = 116 / L = 84

12 1 Pressure cup 838060 R = 132 / L = 100

13 1 Pressure cup 838061 R = 148 / L = 116

14 6 Spring washer 314252 80x41x2.25 (60 – 660 daN)

15 6 Spring washer 314253 80x41x3 (100 – 1050 daN)

16 5 Spring washer 314254 80x41x4 (100 – 2250 daN)

17 1 Pressure spring 836028 Form tool holder >R = 148

18 1 Lubricating nipple 319718

19 1 Banjo fitting 366916

20 1 Hollow-core screw 374179 H1 M5 K

21 2 Bonded seal 361108 USIT U 5.7-9-1


23 1 Pressure cup 838084 R = 170 / L = 138


25 1 Pressure cup 838062 R = 191 / L = 159


27 1 Pressure cup 838086 R = 240 / L = 208

28 1 Cap 838189 RNL/RNEL 281-331 HPP

29 1 Aluminium sealing ring 363681 DA M5

30 1 Block 814151


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



74 803858.011/ENG

11.2.8 Hydraulic aggregate RNE 381 852435-q

Pos. No. Part name Part. No. Remarks

3 2 Straight connection piece 366124 G15LCFX

4 2 Feed cable to valve 520234 L=1500mm

5 1 Feed cable to motor 520169

6 1 Feed cable to motor 520169.01 USA/Canada

10 1 Star knob 390059

11 2 Hydraulic hose 388066 L=2000mm

14 1 Hydraulic aggregate complete 374925 3x220-420V,50Hz/3x255-485V,60Hz

16 1 Hydraulic aggregate complete 374919 3x575V, 60Hz

18 1 Hydraulic aggregate complete 374920 3x200V, 50Hz

35 2 Screw plug 371426 G 1/8“

41 1 Geared pump 381022 WSP10.6,3D0-81E1-LBB/BA-N

42 1 Connecting flange 374951 RBA30/18-M


803858.011/ENG 75

Pos. No. Part name Part. No. Remarks

43 1 Connecting flange 374952 RBA30/10-M

44 1 Intermediate flange with centering disc

374886 LMC200MFS1004E

45 1 Elastic coupling 325211 G-124/1P

46 1 Electric motor 542935 1.1/1.27kW 3x220-240V/380-420V

47 1 Electric motor 542931 1.1/1.3kW 3x575V

48 1 Electric motor 542932 1.1/1.3kW 3x200V

49 1 Oil level indicator 378215 FSA-127-1.1/T/12

50 1 Return line filter with aerating filter 379733 HF554-10129-AS-FG010-B17-GD-B-S-Z

51 1 Glycerine manometer 369806 Ø63 0 – 160bar 1/4B

52 1 Pressure limit cartridge 374946 DVP-2-10-SL max.70bar

54 2 Hydraulic hose 388067 L=2200mm

55 2 Pipe fitting straight 366041 GE 15-L/3/8"

56 1 Casing 852031

57 1 Tube 852032

58 1 Valve block 852122

59 1 Pressure limit cartridge 368108 NG4, DDPC-1L-4-10-H-1

60 1 Glycerine manometer 369809

61 1 Manometer screwed joint 369852 MAV 6-LR

62 2 Pipe fitting straight 366056 GE06LR1/4EDOMDCF


64 1 Swivelling screw-fitting 366921 SWVE 6-PLR

65 1 T-Connection piece 367572 EVT 6-PL

66 1 Sealing cone 371441 BUZ 6-L

67 2 Socket screw 341516 In-6kt with shank M5x50

68 4 Socket screw 341071 In-6kt M5x25

69 2 Plug socket transparent 369349 Type A

70 1 Filter cartridge to return line filter 379734 HEK05-10.129-AS-FG010-VM-B17-B

73 1 4/3-port directional control valve with plug

369512 WEDO-43-J-6-V-1/24V DC-N

74 1 Non-return valve sandwich 369002 SRV.AA-6-S97, with nozzle 0.8

75 1 Non-return valve 369001 RV 3/8“


76 803858.011/ENG

11.2.9 Pressure transmitters fixing 852070-e


1 1 Distributor 852071

2 2 Pressure transmitter 540394 RNE 381/431, 0 – 100bar

3 2 Hydraulic hose 387716 L = 1.3m

4 4 Straight screw fitting 366090 GE 6 PSR ED G 1/4“

5 2 Straight screw fitting 366082 GE 6 PLR ED G 1/8“

6 2 Sealing cone 371441 BUZ 6-L


8 2 Pressure transmitter 540395 RNE 481, 0 – 200bar

9 2 Connection cable to pressure transmitter

540393 L = 2m


803858.011/ENG 77

Headquarter

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 Grossbritannien, Irland 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 (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

Anders Begner, Consultant Jungfrudansen 18 SE-171 56 Solna Schweden

Mobile: 0046 70 520 25 05 [email protected]

Australien Indien 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

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]

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 (Estonia, Latvia, Lithuania) Italien Singapur

CLE Baltic Sära street 10 Peetri village Rae county 75312 Estonia

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

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

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]

Belgien Japan 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

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

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


Brasilien Kolumbien Slowenien, Kroatien

BalTec do Brasil Rua Tiradentes, 1225 – Jardim Florestal Jundiaí – SP CEP 13.215-635 Brasil

Tel.: 0055 11 4492 5408 Fax: 0055 11 4584 7497 Mobile: 0055 11 97531 6113 [email protected]

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

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 Korea 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

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]

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]


China Luxemburg

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



Dänemark Niederlande Südafrika

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

Tel.: 0045 4615 4600 Fax: 0045 4615 4225 Mobile: 0045 405 646 00 [email protected] www.sneholt-nilsen.dk



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 Norwegen 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]

Anders Begner, Consultant Jungfrudansen 18 SE-171 56 Solna Schweden

Mobile: 0046 70 520 25 05 [email protected]

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 Oesterreich, Deutschland PLZ: 83 Tschechien

KLEINIG engineering GmbH 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]

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

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 Polen 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

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

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 Rumänien 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 N. Titulescu Str. 2 RO-500010 Brasov România

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

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]

Frankreich

Russland

USA, Kanada, Mexico

BalTec France 3, rue Joseph Cugnot Zone Artisanale du Patis FR-78120 Rambouillet France

Tel.: 0033 1 61 08 66 10 Mobile: 0033 688 84 88 62 [email protected] www.baltec.fr

ALFLETH ENGINEERING AG Timirayzevskaya 1 RU-127422 Moskau Russia

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

BalTec Corporation 121 Hillpointe Drive Suite 900 Canonsburg, PA 15317, USA

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


78 803858.011/ENG

Radial riveting machine RNE 381 Index

803858.011/ENG 79

12 Index

A

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

Automatic lubrication riveting spindle head ........... 38, 47

B

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

C

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

D

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

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

Decommissioning ....................................................... 55

Dimensions drawing RNE 381 .................................... 15

Dimensions drawing RNE 381 for flange mounting .... 16

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

E

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

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

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

F

Filling of hydraulic oil .................................................. 49

Filter hydraulic aggregate ........................................... 48

Foot switch ................................................................. 39

Form tool D = 20 with various lengths ........................ 26

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

G

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

H

Heating of hydraulic aggregate ................................... 19

Heating of riveting machine ........................................ 19

Hydraulic aggregate .................................................... 48

Hydraulic aggregate motor terminal box ..................... 49

Hydraulic aggregate RNE 381 details ......................... 14

Hydraulic hose lines .................................................... 49

Hydraulic oil ................................................................ 48

I

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

Initiator lower end position (bridging initiator) ............. 41

Initiator upper end position ......................................... 41

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

M

Maintenance and repair log ........................................ 53

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

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

N

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

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

O

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

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

Overview of maintenance work ................................... 43

P

Personal safety equipment ......................................... 19

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

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

Piston and piston rod seals ......................................... 51

Polygon shaft .............................................................. 50

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

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

Pressure pad............................................................... 34

Pressure pad dimensions drawing .............................. 35

Pressure/Force diagram ............................................. 21

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

Production of thrust piece and spring diagram 802296 ............................................................................... 36

Q

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

R

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

Recommended oils ..................................................... 48

Re-commissioning ...................................................... 55

Replaced parts ............................................................ 56

Replacing the form tool holder and pressure cup........ 28

Replacing the pressure cup with the removal device .. 30

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

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

Riveting motor terminal box ........................................ 52

Riveting spindle........................................................... 45

Riveting spindle head (form tool holder and pressure cup) ........................................................................ 44

Riveting stroke adjustment .......................................... 20

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

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

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

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

RNE 381 details .......................................................... 13

S

Schemata .................................................................... 57

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

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

Spare parts lists .......................................................... 59

Index Radial riveting machine RNE 381

80 803858.011/ENG

Standard form tool Ø20 with conical profile (270-431) 32

Standard form tool Ø20 with crowned profile (270-431) ............................................................................... 33

Standard form tool Ø20 with flat profile (270-431) ...... 31

Storage ....................................................................... 55

T

Technical specifications riveting machine 381 ............ 17

Topping up the grease container ................................ 47

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

U

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

V

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

W

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

Workplace ................................................................... 19

radial riveting machine rne...

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