POP NUT PNT800L-PC User manual

PO P
NUT™
Tool
PNT800L-PC
Maintenance Manual

Page 2 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Contents
Introduction ............................................................................................................................................... 3
Safety Instructions .................................................................................................................................... 4
Specifications............................................................................................................................................ 5
Tool Parts .............................................................................................................................................. 6
Packaged Accessories .......................................................................................................................... 6
PNT800L-PC Diagram.............................................................................................................................. 8
Parts List................................................................................................................................................. 10
Tool Setup............................................................................................................................................... 12
Mandrel and Nosepiece installation .................................................................................................... 13
Basic Tool Operation............................................................................................................................... 14
Mandrel & Nosepiece Adjustment ....................................................................................................... 14
Setting Force Valve Spring Selection.................................................................................................. 15
Tool Operation..................................................................................................................................... 16
Setting Force Adjustment........................................................................................................................ 18
Adjustment for Standard POP NUTs™ ............................................................................................... 18
Adjustment for ST & Thin Wall POP NUTs™ ...................................................................................... 18
Adjustment of Setting Force................................................................................................................ 18
Maintenance ........................................................................................................................................... 19
Clean & Lube Mandrel ........................................................................................................................ 19
Lubricate Rotating Parts...................................................................................................................... 19
Recharging Hydraulics ........................................................................................................................ 20
Troubleshooting ...................................................................................................................................... 22
Safety Data ............................................................................................................................................. 24
EC Declaration of Conformity ................................................................................................................. 26

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 3
Introduction
The PNT800L-PC is a small, lightweight tool for installing POP®brand POP NUT™ blind rivet nuts and other
blind threaded inserts by adjusting the setting force to the insert being installed rather than stroke like
traditional blind rivet nut tools. Controlling the setting force has the following benefits:
•No stroke adjustment is needed for the same nut in multiple application grips.
•Eliminated application & nut damage due to “double stroking”.
•Proper set achieved even with a small gap between the nut flange and Nosepiece.
Table 1 lists the POP NUT™ blind rivet nuts that can be fastened using this tool. The Nosepiece and Mandrel
must be changed to fit some sizes of POP NUT™. (See Table 5, Mandrel and Nosepiece Requirements table
in the Specification section)
Table 1: POP NUT™ blind rivet nut range
Material
Thread
Size
Aluminum
Steel
Steel RLT
Stainless
M4X0.7
8-32


M5X0.8
10-24
10-32



M6X1.0
¼-20




M8X1.25
5/16-18


*
*
M10X1.5
3/8-16


* Need to set tool at 0.55 MPa [80 psi] Minimum.

Page 4 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Safety Instructions
TO INSURE PROPER FUNCTIONING AND SAFE OPERATION READ THIS MANUAL
CAREFULLY BEFORE SETTING UP OR OPERATING THE POP NUT SERIES TOOLS
DEFINITIONS:
•CAUTION! – Failure to observe this precaution could result in physical damage
or minor injury.
•WARNING! – Failure to observe this precaution could result in physical damage,
serious injury or even death.
CAUTION!
1. DO NOT use this tool in a manner other than that recommended by Emhart Teknologies.
2. DO NOT modify the tool in any way. Modification will void any applicable warranties and could result
in damage to the tool or physical injury to the user.
3. Disconnect air supply when adjusting, servicing or removing any part of the tool.
4. Trained personnel must perform tool repair and/or maintenance at prescribed intervals.
5. Only use genuine Emhart Teknologies parts for tool maintenance and repair.
6. Do not operate the tool with the Nose Housing removed.
7. Keep fingers away from the front of the tool when connecting the air supply or using the tool.
8. Do not attempt to turn the Mandrel when the air supply is connected.
9. Keep hair, fingers and loose clothing away from moving parts of the tool.
10. Do not direct tool exhaust towards anyone. The tool uses lubricated air and may eject oil mist or
debris.
11. Do not use organic solvents to clean the tool, this may damage the tool.
12. Wash hands thoroughly if exposed to hydraulic fluid or lubricant.
WARNING!
1. DO NOT exceed the maximum recommended air pressure of 0.6 MPa (87 psi / 6.0 bar).
2. DO NOT point the tool at anyone when in use.
3. Always wear safety rated eye protection when using or when near a tool in use.
4. Inspect the tool and connections for damage, worn or loose parts before connecting to the air supply.
If damaged, stop use immediately and have the tool repaired or replaced.
5. This tool is not designed for use in explosive atmospheres.

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 5
Specifications
Table 2: Tool Specifications
Feature
Specification
Weight
1.81 kg (3.99 lbs)
Overall length
287 mm (11.3 in)
Overall height
268 mm (10.4 in)
Tool Stroke
1.3 – 8.5 mm (0.05 - 0.335 in)
Pulling Force
17 kN @ 5.0 bar ( 3824 lbf @ 72.5 psi)
Air Supply
0.5 - 0.6MPa (5 - 6 bar) (72.5 - 87 psi)
Hydraulic Oil
See Table 3, Specified Hydraulic Oils
Setting capacity
See Table 1, POP NUT™ blind rivet nut range
Tool Noise Level
LAeq,T = 72.7 dB(A), LWA = 77.6 dB(A),
LPeak = 106.3 dB(C)
Tool Vibration Level
0.42 m/s2, Time to 2.5 m/s2> 24hrs (EAV)
Figure 1: Tool Dimensions (mm)
Hydraulic oil
Use only Emhart Teknologies specified hydraulic lubrication oils as shown in Table 3.
Use of any other oil could reduce the tool performance or even damage the tool.
Table 3: Specified Hydraulic Oils
Company name
Product name
Mobile
Mobile DTE26
Shell
Shell Telus Oil C68
Idemitsu
Daphne Hydro 68A
Cosmo
Cosmo Olpas 68
Esso
Telesso 68
Nisseki
FBK RO68
Mitsubishi
Diamond Lube RO68 (N)
287
φ22
(59)
(35)
φ27.5
268
85

Page 6 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Tool Parts
Figure 2: Tool Parts Diagram
Packaged Accessories
Table 4: Packaged Accessories
Part No.
Item
Qty
PNT800L-PC-T
PNT800L-PC POP NUT™ Tool
1
PNT600-132
Hook
1
PNT600-133
Hex wrench 1.5 mm
1
DPN907-006
Cap screw M4 X 20
1
DPN277-179
POP NUT™ Mandrel Release
1
DPN901-023
Valve Spring
1
FG2245
Operating Instructions
1
FG2267
Maintenance Manual
1
FG2222
Warranty Card
1
Front Case
Fill Screw
Rear Case
Exhaust Holes
Handle
Swivel Air Fitting
¼NPTF
Air Fitting
(Not Included)
Coupler
(Not Included)
Air Hose
(Not Included)
Chamber
Setting Force
Control Valve
Adjuster
Exhaust Holes
Trigger
Control Knob
Mandrel
Nosepiece/Anvil
Lock Nut
Nose Housing

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 7
Table 5: Mandrel and Nosepiece requirements
Flat Nosepiece
Mandrel
Thick Wall
(Std & ST)
POP NUT
Thread size
Part No.
I.D.
Part No.
Thread size
M4X0.7
PNT600-02-4
φ4.5
PNT600-01-4
M4X0.7
M5X0.8
PNT600-02-5
φ5.1
PNT600-01-5
M5X0.8
M6X1.0
PNT600-02-6
φ6.1
PNT600-01-6
M6X1.0
M8X1.25
PNT600-02-8
φ8.1
PNT600-01-8
M8X1.25
M10X1.5
PNT600-02-10
φ10.1
PNT600-01-10
M10X1.5
8-32
PNT600-02-832
φ4.3
PNT600-01-832
8-32
10-24
PNT600-02-5
φ5.1
PNT600-01-1024
10-24
10-32
PNT600-02-5
φ5.1
PNT600-01-1032
10-32
¼-20
PNT600-02-420
φ6.5
PNT600-01-420
¼-20
5/16-18
PNT600-02-8
φ8.1
PNT600-01-518R
5/16-18
3/8-16
PNT600-02-10
φ10.1
PNT600-01-616R
3/8-16
Piloted Nosepiece
Mandrel
Thin Wall
(TK,TL,TH)
POP NUT
Thread size
Part No.
I.D.
Part No.
Thread size
M4X0.7
PNT600-02-4P
φ4.3
PNT600-01-4P
M4X0.7
M5X0.8
PNT600-02-5P
φ5.1
PNT600-01-5P
M5X0.8
M6X1.0
PNT600-02-6P
φ6.1
PNT600-01-6P
M6X1.0
M8X1.25
PNT600-02-8P
φ8.1
PNT600-01-8P
M8X1.25
M10X1.5
PNT600-02-10P
φ10.1
PNT600-01-10P
M10X1.5
8-32
PNT600-02-4P
φ4.3
PNT600-01-832
8-32
10-24
PNT600-02-5P
φ5.1
PNT600-01-1024
10-24
10-32
PNT600-02-5P
φ5.1
PNT600-01-1032
10-32
¼-20
PNT600-02-420P
φ6.5
PNT600-01-420
¼-20
5/16-18
PNT600-02-8P
φ8.1
PNT600-01-518
5/16-18
3/8-16
PNT600-02-10P
φ10.1
PNT600-01-616
3/8-16
* Refer to the Tool Setup section for details of Nosepiece and Mandrel installation.
I.D.
Thread size
M8X1.0
I.D.
Thread size
M8X1.0

Page 8 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
PNT800L-PC Diagram

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 9

Page 10 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Parts List
Item
Part No.
Description
Qty
1
PNT600-01-6P
Mandrel M6
1*
2
PNT600-02-6
Nose Piece M6
1*
3
PNT600-03
Lock Nut
1
4
PNT600-04A
Nose Housing
1
5
DPN277-001
Spin Pull Head Case
1
6
DPN277-002
Spin Pull Head
1
7
PNT600-07B
Mast Housing
1
8
DPN277-003
Joint
1
9
DPN901-004
Return Spring
1
10
PNT600-10
Housing Lock
1
11
DPN277-004
Hydraulic Piston
1
12
DPN277-005
Rod Seal Case
1
13
DPN908-009
Scraper
1
14
DPN900-031
O-Ring
1
15
DPN908-010
Backup Ring
1
16
DPN908-011
Penta Seal
1
17
DPN908-012
Piston Seal
1
18
DPN900-032
O-Ring
1
19
PNT600-19A
Bit
1
20
PNT600-20
Start Bar
1
21
DPN239-047
Fill Screw
1
22
DPN900-033
O-Ring
2
23
DPN277-006
Lock Pin Holder
1
24
DPN277-007
Lock Pin
1
25
DPN900-034
O-Ring
1
26
PNT600-26
Lock Pin Pusher
1
27
DPN901-009
Spring
1
28
DPN907-005
Socket Head Cap Screw
2
29
DPN907-011
Socket Head Cap Screw
1
30
PNT600-30A
Rear Case Tube
2
31
DPN277-304
Cylinder
1
32
DPN900-015
O-Ring
13
33
PNT600-33A
Joint Adapter
3
34
PNT600-34
Truss Head Screw
3
35
DPN900-035
O-Ring
1
36
DPN277-008
Sleeve Upper
1
37
DPN900-036
O-Ring
1
38
DPN277-009
Handle
1
Item
Part No.
Description
Qty
39
PNT600-039
Truss Head Screw
4
40
DPN277-183
Chamber
1
41
PNT600-41A
R Joint Adapter
1
42
DPN900-021
O-Ring
2
43
PNT600-43
R Joint Spacer
1
44
PNT600-44B
R Joint
1
45
PNT600-45A
Rear Case
1
46
PNT600-46
Truss Head Screw
2
47
DPN277-010
Handle Upper
1
48
DPN277-301
Front Case
1
49
PNT600-49
T Valve End Screw
1
50
DPN900-037
O-Ring
5
51
PNT600-51
Hexagon Thin Nut
2
52
DPN905-004
Socket Set Screw
1
53
DPN277-302
Control Knob
1
54
DPN277-308
Air Tube
1
55
DPN277-303
T Valve Push Rod
1
56
DPN277-011
Trigger
1
57
DPN277-071
Flat Head Screw M3X8
1
58
PNT600-58
Joint Tube
1
59
PNT600-59A
Assist Plate
1
60
DPN900-006
O-Ring
2
61
PNT800-14
Retainer Plate
1
62
DPN908-024
Penta Seal
1
63
DPN908-025
Backup Ring
1
64
DPN277-012
Handle Lower
1
65
DPN277-300
Sleeve
1
66
PNT800-05
Tube
1
69
DPN900-038
O-Ring
1
70
DPN900-039
O-Ring
1
71
PNT600-71
Washer
1
72
PNT600-72
Tube Seal Case
1
73
DPN900-011
O-Ring
2
74
DPN909-001
SS-Washer
1
75
DPN900-040
O-Ring
1
76
DPN900-023
O-Ring
1
77
FAN277-299
Air Piston Assembly
1
78
PNT800-07A
J Valve Stopper
1

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 11
Item
Part No.
Description
Qty
79
PNT800-08A
J Valve Rod
1
80
DPN900-014
O-Ring
6
81
DPN901-010
Spring
1
83
DPN239-065
J Valve Cap
1
84
PNT800-10
T Valve Rear Case
1
85
DPN900-013
O-Ring
1
86
DPN901-011
Spring
1
87
PNT800-11
T Valve Center Case
1
88
PNT800-12
T Valve Front Case
1
89
DPN900-041
O-Ring
5
90
PNT600-90
T Valve Cap
1
91
PNT600-91
T Valve Front Piece
1
92
PNT600-92
T Valve Rod
1
93
PNT600-93
S Valve End
1
94
DPN900-012
O-Ring
2
95
DPN902-001
Retaining Ring
1
96
PNT600-96
S Valve Rod
1
97
PNT600-97B
S Valve Case
1
140
DPN277-309
Fitting
1
132
FAN277-311
Setting Force Control Valve
1set
133
DPN277-306
Adjuster
1
134
DPN901-023
Valve Spring
1
136
DPN277-305
Valve
1
32
DPN900-015
O-Ring
1
138
DPN905-006
Socket Set Screw
1
139
DPN277-307
Valve Case
1
140
DPN277-309
Fitting
1
141
DPN907-008
Socket Head Cap Screw
2
200
PNT600-200
Air Motor
1set
60
DPN900-006
O-Ring
2
80
DPN900-014
O-Ring
2
98
PNT600-98B
M Valve End
1
99
DPN900-042
O-Ring
1
100
DPN277-177
Flat Head Screw
1
101
PNT600-101A
Motor Case End Plate
1
102
DPN900-043
O-Ring
1
103
PNT600-103
M Valve Rod
1
104
PNT600-104
Motor Case End
1
105
PNT600-105
Washer
1
106
DPN900-044
O-Ring
1
Item
Part No.
Description
Qty
107
PNT600-107
O-Ring Holder
1
108
DPN900-045
O-Ring
1
109
DPN902-002
Retaining Ring
1
110
PNT600-110
Casing
1
111
PNT600-111
Ball Bearing
1
112
PNT600-112
Rear Plate
1
113
PNT600-113
Rotor
1
114
PNT600-114
Blade
4
115
PNT600-115
Spring Pin
1
116
PNT600-116
Cylinder
1
117
PNT600-117
Front Plate
1
118
PNT600-118
Ball Bearing
1
119
PNT600-119
Spacer
1
120
PNT600-120
Sun Gear
1
121
PNT600-121
Planet Gear
6
122
PNT600-122
Needle pin
6
123
PNT600-123
Gear Cage & Gear
1
124
PNT600-124
Spacer
1
125
PNT600-125
Internal Gear
1
126
DPN901-012
Spring
1
127
PNT600-127
Gear Cage
1
128
PNT600-128
Spacer
1
129
PNT600-129
Ball Bearing
1
130
DPN902-003
Retaining Ring
1
131
DPN902-004
Retaining Ring
1
Accessories
135
DPN901-024
Valve Spring
1
142
PNT600-132
Hook
1
143
PNT600-133
HS Screw Key, 1.5mm
1
144
DPN907-006
Socket Head Cap Screw
1
145
PNT600-01-4
Mandrel, M4
1
146
PNT600-01-5P
Mandrel, M5
1
147
PNT600-01-8
Mandrel, M8
1
148
PNT600-02-4
Nose Piece, M4
1
149
PNT600-02-5
Nose Piece, M5
1
150
PNT600-02-8
Nose Piece, M8
1
151
DPN277-179
POP NUT Mandrel Release
1
*See table 5 for additional Mandrels and Nosepieces

Page 12 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Tool Setup
Initial Setup
1. Check that the correct Nosepiece and Mandrel are fitted for the POP NUT™. See the Basic
Tool Operation section for proper tool adjustment.
2. Connect an air fitting to the Swivel Air Fitting of the tool. The Swivel Air Fitting is a 1/4 NPTF
thread.
3. Connect an Air Hose to the tool.
4. Connect an air filter, regulator and lubricator in the air line between the air supply and Air Hose
connecting to the tool, within 3m [6 ft ] of the tool.
5. Adjust the air pressure supply and oil drip volume of the lubricator
•Air Pressure: 0.5-0.6 MPa. (72.5-87 psi)
•Oil drip volume: 1-2 drops/ 20 nuts fastened
Figure 3: Tool Setup
Note: Refer to the instruction manual for the Lubricator used for the proper adjustment method and
lubrication oils to use relating to air motors.
WARNING!
Use an air hose with a rating of 1.0 MPa (145 psi / 10 bar) or greater maximum ordinary operating
pressure. Also make sure the hose material is suitable for the operating environment (i.e. oil proof, wear
and abrasion resistance etc.). For details, refer to your hose manufacturer's catalog.

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 13
Mandrel and Nosepiece installation
Mandrel Installation
1. Disconnect the Air Supply
2. Select the correct Mandrel according to Table 5.
3. Remove the Nosepiece from the tool by loosening the Lock Nut and unscrewing it.
4. Insert the POP NUT™ Mandrel Release tool over the Mandrel and into the Nose Housing.
5. Push in to disengage the Lock Pin Holder from the Mandrel.
6. While holding the Mandrel Release in, unscrew the Mandrel by turning it counter-clockwise.
7. While holding the Mandrel Release in, screw in the desired Mandrel until it stops.
8. Release the Mandrel Release and rotate the Mandrel counter-clockwise to ensure the Lock Pin
Holder has engaged the Mandrel.
9. Replace the Nosepiece.
Figure 4: POP NUT™ Mandrel Release
Mandrel Installation (without POP NUT™ Mandrel Release, DPN277-185)
10. Disconnect the Air Supply
11. Select the correct Mandrel according to Table 5.
12. Remove the Nose Housing from the tool to expose the Mandrel and Spin Pull Head Case.
13. Pull the Lock Pin Holder back and unscrew the Mandrel by turning it counter-clockwise.
14. While holding the Lock Pin Holder back, screw in the desired mandrel until it stops.
15. Release the Lock Pin Holder.
Note: If the Lock Pin Holder does not return to its original position then turn the Mandrel
counter-clockwise to ensure the Lock Pin engages the Mandrel and the holder moves forward.
16. Replace the Nose Housing.
Figure 5: Mandrel Installation
Nosepiece Installation
1. Disconnect the Air Supply
2. Select the correct Nosepiece according to Table 5.
3. Remove the current Nosepiece from the tool by loosening the Lock Nut and unscrewing it.
4. Remove the Lock Nut from the Nosepiece
5. Thread the Lock Nut onto the desired Nosepiece
6. Screw the Nosepiece into the Nose Housing
7. Lock it in place by tightening the Lock Nut against the Nose Housing
Nose Housing
Mandrel
Mandrel
Spin Pull Head Case
Lock Pin Holder
PULL
POP NUT™
Mandrel Release
Mandrel
PUSH

Page 14 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Basic Tool Operation
Before setting POP NUTs™ with this tool, refer to the Safety Instructions and Tool Setup sections
of this manual to ensure safe and reliable tool operation.
Mandrel & Nosepiece Adjustment
1. Verify that the correct Mandrel and Nosepiece are fitted to the tool for the desired POP NUT™
(See Mandrel and Nosepiece Requirements table in the Specifications section).
Figure 6: Nosepiece and Lock Nut
2. Loosen the lock nut on the tool and thread the Nosepiece all the way into the Nose Housing.
3. Thread the desired POP NUT™ onto the tool.
Open End POP NUTs™
a. Thread the insert onto the mandrel until the Mandrel extends beyond the insert by
approximately 1 full thread
b. Unthread the Nosepiece until it is touching the flange of the insert
c. Tighten the lock nut against the Nose Housing.
Closed End POP NUTs™
a. Thread the insert onto the mandrel until it stops
b. Unthread the insert on full turn (one thread pitch)
c. Unthread the Nosepiece until it is touching the flange of the insert
d. Tighten the lock nut against the Nose Housing.
Figure 7: Proper Mandrel and Nosepiece adjustment
Nosepiece/Anvil
Lock Nut
One Thread
One Thread
Open End
Closed End

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 15
Setting Force Valve Spring Selection
•There are two types of spring used with the PNT800L-PC tool depending on the insert being
used.
•Review the table below and select the proper Valve Spring for the insert being used.
Table 6: Setting Force Valve Springs for Standard & Thick Wall inserts
Material
Thread
Size
Aluminum
Steel
RLT
Stainless
M4
8-32
-
-
DPN901-023
DPN901-023
M5
10-24
10-32
-
DPN901-023
DPN901-023
DPN901-023
M6
1/4-20
DPN901-023
DPN901-023
DPN901-024
DPN901-023
M8
5/16-18
DPN901-023
DPN901-024
DPN901-024*
DPN901-024*
Thick Wall
(Std & ST)
M10
3/8-16
DPN901-023
DPN901-024
-
-
* Need to set tool at 0.55Mpa Minimum.
Table 7: Setting Force Valve Springs for Thin Wall inserts (TK, TL, TH)
Thread
Size
Steel
M4
8-32
DPN901-023
M5
10-24
10-32
DPN901-023
M6
1/4-20
DPN901-023 /
DPN901-024
M8
5/16-18
DPN901-024
Thin Wall
(TK, TL, TH)
M10
3/8-16
DPN901-024
Figure 8: Valve Springs
25 mm
[0.98 in]
20 mm
[0.79 in]
DPN901-023:
DPN901-024:

Page 16 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Tool Operation
Loading the POP NUT™ onto the tool
1. Connect the air supply to the tool.
2. Thread the insert 1/4 turn onto the Mandrel.
3. Press the insert against the Mandrel as indicated and the Mandrel will spin, automatically
threading the insert onto the Mandrel.
4. Keep pushing the insert onto the Mandrel until the Mandrel stops spinning. If the insert is not
fully threaded, the setting stroke will be shortened by the gap between the head of the insert and
the Nosepiece.
Figure 9: Loading the POP NUT™ onto tool
Installing the POP NUT™ into the work piece
1. With the POP NUT™ mounted on the Mandrel, insert it perpendicularly into the hole of the work
piece
2. Pull the trigger and hold it to install the insert
3. Keep trigger depressed until the Mandrel reverses direction and completely unthreads the
Mandrel from the insert.
4. Lightly pull the tool away from the work piece as Mandrel is reversing to disengage it from the
insert.
5. Once the tool is disengaged from the insert, release the trigger.*
Figure 10:Setting the POP NUT™
Note:
•Fit the flange of the insert flat against the work piece.
•Do not tilt the tool. The tool must be perpendicular to the work piece.
OK
Not OK
Gap
PULL
Work piece
Trigger
HOLD
LIGHTLY PULL
RELEASE

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 17
Figure 11: Proper insertion of POP NUT™ threaded inserts into an application
*Disengaging the tool from the insert
•If you let go of the trigger during the installation sequence, the hydraulics will reset, the insert may
not set completely and the tool will not unthread from the insert. Do not pull the trigger again,
follow the steps below to disengage the insert.
To disengage the tool from the insert and application:
1. Depress and hold the Control Knob
2. While holding the Control Knob, press and hold the trigger. This will cause the Mandrel to spin
counter-clockwise and unthread the insert.
3. When fully unthreaded, release the trigger.
To disengage the tool from the insert and work piece if the Mandrel is stuck:
1. Disconnect the air supply
2. Thread the M4 x20 Cap screw provided with the tool, into the hole in the side of the Nose
Housing. Thread the Cap screw in until if fits snugly against the inner Spin Pull Head, locking
the rotatioin of the Mandrel to the tool.
3. Turn the body of the tool counter-clockwise to detach it from the insert.
Figure 12: Disengaging the tool from the insert
OK
Not OK
Gap
Not OK
ROTATE
1. Control Knob
2. Trigger
Cap Screw
Nose Housing
Spin Pull Head

Page 18 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Setting Force Adjustment
•Verify the proper Valve Spring is selected – See “Setting Force Valve Spring Selection“
•Adjust the setting force of the tool according to insert size and thickness of work piece as
indicated in the instructions below.
•Test 5 pieces before beginning production work to ensure proper setting of the POP NUT™.
•Proper setting force is critical:
oLow setting Force results in insufficient stroke and clamping of the insert, leading to a
Spin Out failure in the application
oHigh setting force results in excess stroke and possible insert threads stripping and
Mandrel damage
Adjustment of Setting Force
The following is the procedure for adjusting the Setting Force:
1. Loosen Socket Set Screw on Setting Force Control Valve.
2. Turn the Adjuster using a flat blade screwdriver as needed.
a. Adjust Setting force by 1/4 turn increments to prevent stripping or damaging of insert
threads.
3. Tighten Socket Set Screw on Setting Force Control Valve.
DESIRED EFFECT
ACTION
Increase Setting Force (Increases Stroke)
Rotate Adjuster Clockwise
Decrease Setting Force (Decreases Stroke)
Rotate Adjuster Counter-Clockwise
Figure 13: Adjustment of Setting Force
Note:
•The stoke may increase or decrease due to changes in air pressure [~0.1 mm (0.004 in) per 0.1
MPa (15 psi)]
•Multiple work piece thicknesses
oWhen using the POP NUT™ tool to set the same insert in multiple work piece
thicknesses, adjust the setting force to accommodate the thinnest work piece.
WARNING!
Adjust Fastening Load Control Valve by 1/4 rotations.
If the Adjuster is rotated clockwise by a large amount to increase the setting force it may cause stripping or
sticking of Mandrel and/or POP NUT™ threads.
Adjuster
Socket Set Screw
Setting Force
Control Valve

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 19
Maintenance
Table 8: Maintenance Schedule
Item
Frequency
Details
Lubricate Air
1-2 drops/20 sets
•See “Tool Setup”
•Lubricates internal seals and Air Motor
Clean & Lube Mandrel
50 sets
•Replace if worn/damaged
•Prevents insert damage or jamming.
Inspect Nosepiece
50 sets
•Replace if worn/damaged
•Prevents insert damage or jamming.
Lubricate rotating parts.
1000 sets
•Prevents loss of Mandrel rotation force.
Inspect Control Nut, T Valve Push Rod.
Mandrel breakage
•Replace if bent or broken
Recharge hydraulics
Loss of Stroke
•See “Recharging Hydraulics”
Clean & Lube Mandrel
•Clean and Lube the Mandrel every 50 sets.
oOver time, debris can stick to the Mandrel reducing its lubrication making it difficult to
mount POP NUTs™ or causing premature wear or jams.
oLube the Mandrel with 1 drop of oil. Use the same oil that is used with the Air Lubricator
or an ISO VG 32 type oil.
Figure 14: Clean and Lube Mandrel
Lubricate Rotating Parts
•Lubricate the Spin Pull Head and Spin Pull Head Case after approximately every 1000 sets.
oLack of lubrication will cause increase internal friction causing premature wear and
reducing the Mandrel rotation speed and torque
Figure 15: Lubricating the Spin Pull Head
Spin Pull Head
Spin Pull Head Case

Page 20 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Recharging Hydraulics
•If the stroke gets too short and the tool is unable to properly set an insert the Hydraulic Oil may
need to be recharged.
Note: If the stroke is still inadequate after recharging, the Hydraulic Seals may need to be
replaced. Contact your local distributor for tool repair.
Recharging Procedure
1. Disconnect the air supply
2. Remove Air Tube from the fitting in the Chamber
3. Remove the four (4) truss head machine screws attaching the Chamber to the Handle Lower
4. Turn the tool upside down and slowly remove the Chamber from the tool
5. Remove the Air Piston Assembly and the Tube
Figure 16: Removing the Chamber and Air Piston Assembly
6. Dispose of the old hydraulic oil in a proper waste oil container
7. Pour the new hydraulic oil into the bore of the handle until the oil is level with the Back-up Ring
Note: Use only Emhart approved Hydraulic Oils – See Table 3, “Specified Hydraulic Oils”
Figure 17: Re-filling Hydraulic Oil
8. Replace the Air Piston Assembly and push it into the Handle slowly, 5 times, and then remove it
9. Check to see if the oil level has fallen or if there are air bubbles present in the oil
10. If the oil level has dropped or air bubbles are present, repeat steps 7 thru 9
Chamber
Air Tube
Air Piston Assembly
Tube
Chamber
Handle Lower
Handle Lower
Truss Head Screw (X 4)
Handle
Oil
Back-up Ring
Penta Seal
Handle