Cardinal 9991 User manual

9991
Pneumatic Hex Hole Cutting Tool for
1032-1/2 (M5-M12)
Blanket Orders - Level III PPAP’s - In Business Since 1983
ISO 9001 ISO CERTIFIED
800.236.3200 - [email protected]
RIVETNUTUSA.COM
A division of Cardinal Components, Inc.

GENERAL INFORMATION
ASSISTANCE
In case you need any assistance concerning the use and the maintenance of the tool, or in case you need to order
any spare parts, you shall contact your local authorized dealer specifying the identification/serial numbers of the
tool, written on its outer casing.
CERTIFICATION AND EC MARKING
The tool is manufactured in compliance with the European Directives, which are in force when the tool itself is
put on the market.
MANUAL STRUCTURE
This instruction manual must be read with particular attention by the Customer, as the correct pre-arrangement,
installation and use of the tool, are the correct basis for a good relationship between Manufacturer and Customer.
PURPOSE AND CONTENTS
The manual herein has the purpose of providing the Customer with all the information needed not only to use the
tool correctly, but also to manage it self-sufficiently and safely. It includes information concerning technical aspects,
operation, maintenance, spare parts and safety.
Users and Qualified Technicians must read the instructions given herein thoroughly before starting to use the
tool. If you have any doubts on the meaning of the instructions given, please do not hesitate to contact us for
further explanations.
RECEIVERS
The manual herein has been written for both the operators and the technicians enabled to service the tool. Operators
must not carry out jobs reserved to service and/or qualified technicians.
Cardinal Components Inc is not liable for any damage deriving from the failed observance of this rule.
PLACING OF THE MANUAL
This instruction manual must be kept near the tool, inside a dedicated container and, above all, away from liquids or
anything else that may compromise its legibility.
OPERATING SYSTEM
The hydro-pneumatic hexcutter tool for hexagonal holes, 9991, is used for hexagonal rivet nuts.
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
2

AIR WORKING PRESSURE 90 PSI / 6 BAR
MAX AIR PRESSURE 70 to 100 PSI / 5 to 7 BAR
AIR CONSUMPTION 152 cu. in.
PER CYCLE AT 6 BAR 2.5 liter
MAX STROKE .472” / 12 mm
DRIVING FORCE 4721 lbs. @ 90 PSI
21 kN @ 6 BAR
WEIGHT 5.3 lbs. / 2.4 kg
VIBRATIONS < 2.5 m/s2
NOISE LEVEL 80 dB (A)
The hydro-pneumatic system and the mechanical components used in the inside structure of 9991, when compared
with other riveting tools, result to be much more reliable. A tool feature is a reduction of the problems caused by the
wear and tear of the components, and consequently the tool will last much longer and work better. The technical
solutions adopted make the 9991 more compact and lighter: the result is a very handy tool.
VIBRATION
When used correctly, the tool does not produce any dangerous vibration.
NOISE LEVEL
The tool is designed and manufactured in such a way that the noise level is very low. The weighed equivalent
continuous acoustic pressure level A in the operator position is indeed below 80 dB (A).
This information can allow the tool user to better evaluate the possible risks of danger.
TECHNICAL DATA
The following table provides the technical data and features of the tool, to which you must refer when contacting the
Cardinal Components Inc., Technical Assistance Department.
TECHNICAL DATA AND FEATURES
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
3

EQUIPMENT
The equipment stated hereafter refers to standard tools.
Any special tool could consequently require special parts, different than those listed.
REF. PART NUMBER QTY DESCRIPTION
1 4630400 1 9991-HYDRO-PNEUMATIC PUNCHING TOOL (IN CASE)
2 3064400 1 HYDRAULIC OIL TYPE ISO VG 32 100CC
3 3077300 1 PLASTIC CASE
– – 1 INSTRUCTION MANUAL
1 2 3
PART NUMBER DESCRIPTION
2974900 M5 HEXAGONAL PUNCH FOR RIVET NUT HEXAGON 7
2925000 M6 HEXAGONAL PUNCH FOR RIVET NUT HEXAGON 9
2975000 M8 HEXAGONAL PUNCH W/RING HEXAGON 11
NUT FOR RIVET NUT
2975300 M5 DIE WITH RING NUT FOR PUNCH HEXAGON 7
2925100 M6 DIE WITH RING NUT FOR PUNCH HEXAGON 9
2975400 M8 DIE WITH RING NUT FOR PUNCH HEXAGON 11
4631900 M10 COMPLETE KIT FOR RIVET NUT HEXAGON 13
4669200 M12 COMPLETE KIT FOR RIVET NUT HEXAGON 16
OPTIONAL TOOLING
The tool can be supplied with the following options:
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
4

Predrilled * Hexagon * Plate Thickness
Size inches / mm inches / mm Aluminum Steel Stainless Steel
inches / mm inches / mm inches / mm
#10-32 / M5 .285 / 7.25 .276 / 7 .020-.197 / 0.5-5.0 .020-.118 / 0.5-3.0 .020-.059 / 0.5-1.5
1/4-20 / M6 .364 / 9.25 .354 / 9 .020-.236 / 0.5-6.0 .020-.118 / 0.5-3.0 .020-.059 / 0.5-1.5
5/16-18 / M8 .443 / 11.25 .433 / 11 .020-.236 / 0.5-6.0 .020-.118 / 0.5-3.0 .020-.059 / 0.5-1.5
3/8-16 / M10 .522 / 13.25 .512 / 13 .020-.236 / 0.5-6.0 .020-.118 / 0.5-3.0 .020-.059 / 0.5-1.5
1/2-13 / M12 .640 / 16.25 .630 / 16 .020-.236 / 0.5-6.0 .020-.118 / 0.5-3.0 .020-.059 / 0.5-1.5
HOLES SIZES AND PLATE THICKNESS
COMPLETE KIT FOR HEXAGON 13 FOR M10 RIVET NUT
REF. PART NUMBER QTY DESCRIPTION
1 2975500 1 DIE WITH RING NUT FOR PUNCH HEXAGON 13
2 4644500 1 SLEEVE FOR M10
3 4669500 1 HEXAGONAL PUNCH FOR M10 RIVET NUT HEXAGON 13 WITH RING NUT
4 4527500 1 PISTON CONNECTION
KIT COMPOSITION
REF. PART NUMBER QTY DESCRIPTION
1 4631900 1 KIT991-10 - COMPLETE KIT FOR HEXAGON 13 FOR M10 RIVET NUT
2 3 41
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
5

COMPLETE KIT FOR HEXAGON 16 FOR M12 RIVET NUT
REF. PART NUMBER QTY DESCRIPTION
1 4669300 1 DIE WITH RING NUT FOR PUNCH HEXAGON 16
2 4644600 1 SLEEVE FOR M12
3 4669400 1 HEXAGONAL PUNCH FOR M12 RIVET NUT HEXAGON 16 WITH RING NUT
4 4527500 1 PISTON CONNECTION
KIT COMPOSITION
REF. PART NUMBER QTY DESCRIPTION
1 4669200 1 KIT991-12 - COMPLETE KIT FOR HEXAGON 16 FOR M12 RIVET NUT
2 3 41
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
6

ASSEMBLY FOR M10 KIT (4631900) AND M12 KIT (4669200)
Unscrew with
17mm wrench
Hold tight with
39mm wrench
Assemble M10 or M12 kit
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
7

SPARE PARTS
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
8

REF. PART NUMBER QTY DESCRIPTION REF. PART NUMBER QTY DESCRIPTION
1 3066500 1 SNAP RING 24 3067500 2 O-RING 113
2 3066400 1 O-RING 25 3065900 1 STEM
3 3066300 1 BOTTOM 26 4617400 1 PNEUMATIC CASING
4 4616900 1 AIR PISTON 27 3072600 1 NUT
5 3066100 1 O-RING 28 3066600 1 RUBBER BASE
6 3066000 1 SHOCK ABSORBER 29 3070900 1 SPOOL
7 3235500 1 CONNECTION THREAD 1/4” + 1/4” GAS + 30 3069400 1 CAGE
ALUMINUM WASHER
8 3538300 1 SEAL WASHER 31 3071300 3 CAGE
9 3068400 2 O-RING 32 3071100 1 THREAD CAP
10 3068500 1 O-RING 33 3071000 5 O-RING
11 3068600 1 STEM GUIDE 34 3070800 1 O-RING
12 3068700 1 O-RING 35 3070700 1 O-RING
13 3068800 1 SPRING 36 3070600 1 THREAD CAP
14 3095200 1 OIL CAP 37 3119800 1 PISTON CONNECTION
15 3095600 1 POINTED NUT M3 X 3 38 3119900 1 RING NUT
16 3096100 1 PIN 39 4644000 1 SLEEVE
17 3070300 1 TRIGGER 40 4631400 1 STOPPING DEVICE WITH O-RING
18 3070400 1 TRIGGER PIN 41 4631500 1 GASKET
19 5033800 1 HYDRAULIC CASING 42 4631600 1 HYDRAULIC PISTON
20 3094900 1 PIN 43 4631700 1 SPRING
21 3072800 1 MUFFLER 44 4631800 1 BOTTOM
22 3098300 2 GASKET 45 3118800 1 M10 PLIERS OPENER BAR FOR M4 - M10
RIVET NUTS
23 3068200 1 RING NUT
NOTE: When placing an order, please indicate the REF. number and the DESCRIPTION.
TABLE FOR SPARE PARTS DIAGRAM
REF. PART NUMBER QTY DESCRIPTION
1 4644400 1 SLEEVE
2 3119900 1 RING NUT
3 3119800 1 PISTON CONNECTION
2 31
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
9

GENERAL WARNINGS
The operator must read carefully the information given in the present manual, especially with regard to the safety
precautions listed in this chapter. The operator must also observe the warnings listed below:
• The tool shall be used exclusively by trained personnel.
• The tool and the work area shall be kept clean and tidy.
• The tool shall be rested upright on the rubber base on a flat surface to prevent it from falling.
• The tool shall only be used in normal operating conditions.
• The user shall wear suitable clothing taking care to avoid entanglement of loose parts, ties, long hair, cleaning
rags etc. in the tool itself.
• When using the tool, the operator and others nearby should wear safety glasses to protect against fastener
ejection. We also recommend wearing gloves when using the tool.
• The user shall use the accessories supplied when servicing and/or adjusting the tool.
• The plates applied on the tool shall not be removed or altered.
• Unauthorized personnel shall not be allowed to touch the tool.
• Make sure that the air supply hoses are correctly sized.
• Do not drag the tool holding it by the hose when it is connected to the power supply. Keep the hose away from
sources of heat and from sharp objects.
• Remember to remove service or adjustment keys after having making a repair and/or adjustment.
• Before disconnecting the compressed air hose from the tool, ensure it is not pressurized.
• Disconnect the air supply before cleaning or making tool repairs.
• Air supply must be disconnected before making tool repairs and cleaning.
• When filling with oil, only use fluids with the characteristics indicated herein.
• If you should accidentally spill oil on your skin, rinse and wash thoroughly with soap and water.
• Where possible, you are recommended to use a safety balance to support the tool.
• Pay attention to possible risk of whiplash with the air supply hoses.
• Do not operate the tool when it is directed towards anyone.
INTENDED USE
The tool is designed exclusively to transform round holes into hexagonal.
UNINTENDED USE
The tool shall not be used:
• In explosive or aggressive atmosphere or when there is an excessive amount of dust or oil in the air.
• In atmosphere subject to the risk of fire.
• When it is exposed to weather conditions.
RESIDUE RISK
During the normal working cycle and when servicing the tool, the operators are exposed to some residue risks
which, due to the nature of the operations to be carried out, cannot be totally eliminated.
It is therefore absolutely crucial not to exceed the maximum pressure indicated in the technical data section on
page 3.
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
10

IDENTIFICATION/SERIAL NUMBER
HANDLING
The tool can be hand carried. It is recommended to store the tool in its case after using it.
The tool can be transported safely if is has been correctly put away in its case.
Damages to the tool caused during transport and/or handling are not covered by WARRANTY.
Repairs or replacements of damaged parts are at Customer’s charge.
STORAGE
If you are not going to use the tool for a long time, you must put it away according to the following suggestions:
• Store the tool indoors.
• Protect the tool from impacts and stresses by keeping it in its case.
• Protect the tool from damp and excessive heat.
• Keep the tool away from corrosive substances.
CONNECTIONS
To avoid problems when starting the tool, observe the following:
PNEUMATIC
The pneumatic line is connected by a quick-release coupling hose to be
attached to the air connection, thread size 1/4” + 1/4” gas, supplied with
the tool. The air supply hose must be flexible and must meet the safety
requirements of the tool.
AIR SUPPLY
The air supply line must be free from dirt and moisture to prevent early wear of moving components on the tool.
Therefore, it is recommended to use dry air: i.e. not greased.
Model and serial number
etched in the outer casing
Adhesive label indicating the tool model, the
name of the manufacturer and the EC marking
1/4” + 1/4”
gas air connector
Request
your quote with Rivet Nut USA (a division of Cardinal Components,
Inc.)
Cardinal
Components is your authorized preferred distributor.
[email protected] | [phone]
11

PRELIMINARY CHECKS
Before putting the tool into service you need to make a few inspections and checks in order to prevent errors or
accidents while starting it.
• Check if the tool has been damaged during transportation.
• Check if the compressed air hose is accurately connected to the air supply line.
• Check if the tool turns freely and if the motor runs freely.
OPERATORS
The tool is designed to be used by one operator only.
Tool operators must satisfy the requirements stated hereafter (or they must be informed and trained accordingly).
They must be aware of the manual herein and of all information relevant to safety:
• They must have some general and technical education, to a sufficient level to be able to understand the manual
and to interpret the drawings and the diagrams correctly.
• They must be acquainted with the safety rules, and with the industrial-safety and technical instructions.
• They must have an overall knowledge of the line and of the factory in which the tool is installed.
• They must know how to act in case of emergency, where to find the individual protection means and how to use
them correctly.
Together with the above-mentioned requirements, the service technicians must also have appropriate technical
training.
TOOL PREPARATION
Warning: Disconnect the air line before setting up the tool.
SERVICING THE TOOL AND REPLACING THE PUNCHES AND DIE
(See diagram above)
Before using the tool and after every size change, you need to:
• Take the sleeve off
• Insert the punch inside the proper ring nut
• Screw the sleeve on but don’t cover the cylindrical end of the punch
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
12

MAINTENANCE
Maintenance operations must be carried out with the tool stopped and disconnected from the pneumatic supply line.
Warnings:
• The tool maintenance instructions must be followed carefully.
• To ensure safety and perfect tool efficiency, it is recommended to use exclusively ORIGINAL spare parts.
CLEANING
It is a good rule to completely clean and grease the tool on a periodic basis (depending on the type and frequency of
use). These operations must be carried out at least once a year.
Shut-off all sources of power to the tool.
The operator must wear and use suitable personal protections before starting to clean the tool.
ORDINARY MAINTENANCE
In order to prevent stoppages and faults of the tool, an ordinary maintenance (including inspections, checks and
operations) must be scheduled to keep the following under systematic control:
• State of lubrication of the tool.
• State of wear of consumable parts.
REFILLING THE HYDRAULIC CIRCUIT WITH OIL
Disconnect air line to prime tool. Proceed as follows (see photo above):
• Disconnect the airline from the tool inlet.
• Unscrew the screw.
• Remove the cap.
• Put the tool in a horizontal position and slowly pour the hydraulic oil (32˚ viscosity) in the cap until the circuit is
full.
• Block the screw.
• Screw cap back on.
• Connect the tool to compressed air line and start up a couple of idle cycles.
Wear gloves when managing the oil.
Do not throw the old oil outdoors. Hand it over to an authorized waste disposal center.
Warning!: If you should accidentally spill oil on your skin, wash and rinse thoroughly with soap and water.
Screw
Cap
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
13

PARTS SUBJECT TO WEAR
On a periodic basis check the rubber base for wear, as this is what ensures the stability of the tool. If it should need
replacing, order the spare base from Cardinal Components Inc., customer service indicating the year/serial
number of the tool.
On a periodic basis check the wear of both the punch and hexagonal die.
FAULT DIAGNOSIS AND REPAIRS
REPAIRS
To ensure the operational efficiency and safety of the tool, all repair jobs shall be carried out exclusively by
shipping your tool to Cardinal Components Inc.
REQUESTING ASSISTANCE
For any information concerning Use, Maintenance, Installation, Repair etc., contact Cardinal Components Inc.,
customer service. When making inquiries, the customer is requested to be absolutely clear and to always refer to
this Manual.
DISMANTLING INSTRUCTIONS
DISMANTLING INSTRUCTIONS
When disposing the tool you need to separate the plastic parts, which are to be disposed of in compliance with
current Regulations.
As for the bulk metal part of the tool, simply split-up the steel parts from those in other metals or alloys and send to
be melted down and recycled.
The oil drained from the tool must not be thrown outdoors but handed over to an authorized oil disposal center.
Request your quote with Rivet Nut USA (a division of Cardinal Components, Inc.)
Cardinal Components is your authorized preferred distributor.
[email protected] | [phone]
14