Pop NUT PNT800A User manual

POP NUT™
Tool
PNT800A
Maintenance Manual

Page 2 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
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Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 3
Contents
Introduction...............................................................................................................................................3
Safety Instructions....................................................................................................................................5
Specifications ...........................................................................................................................................6
Tool Parts..............................................................................................................................................7
Packaged Accessories..........................................................................................................................7
Tool Set Up...............................................................................................................................................8
Stroke Adjustment ....................................................................................................................................9
Basic Tool Operation ..............................................................................................................................14
PNT800A Diagram .................................................................................................................................18
Parts List ................................................................................................................................................20
Maintenance and Testing........................................................................................................................22
Troubleshooting......................................................................................................................................28
Safety Data.............................................................................................................................................30
EC Declaration of Conformity.................................................................................................................31
Introduction
The PNT800A is a small, lightweight tool for installing POP®brand POP NUT™ blind rivet nuts and
other blind threaded inserts. It is driven by compressed air.
Table 2-1 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 2-2)
Table 2-1 Tool capacity
Thread Size
M3 M4 M5 M6 M8 M10
POP NUT Type Material
6-32 8-32 10-24 /
10-32 1/4-20 5/16-18 3/8-16
Steel 333333
Aluminum 333333
Standard nut
Stainless 33333
Steel 333333
Aluminum 333333
Closed End nut
Stainless 33333
Steel 33333
Hexgonal nut Aluminum 3333
Square nut Steel 3333
Knurled nut Steel 3333

Page 4 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Table 2-2
Flat Nosepiece Mandrel
Thick Wall
POP NUT
Thread
size
POP NUT Tool
Part No.
Part No. I.D. Part No.
Thread
size
M3×0.5 PNT800A-3 PNT600-02-3 Φ4.0 PNT600-01-3 M3×0.5
M4×0.7 PNT800A-4 PNT600-02-4 Φ4.5 PNT600-01-4 M4×0.7
M5×0.8 PNT800A-5 PNT600-02-5 Φ5.1 PNT600-01-5P M5×0.8
M6×1.0 PNT800A-6 PNT600-02-6 Φ6.1 PNT600-01-6P M6×1.0
M8×1.25 PNT800A-8 PNT600-02-8 Φ8.1 PNT600-01-8 M8×1.25
M10×1.5 PNT800A-10 PNT600-02-10 Φ10.1 PNT600-01-10A M10×1.5
M4,M5,M6
set PNT800A
6 – 32 PNT800A-632R PNT600-02-632 Φ3.6 PNT600-01-632 6 – 32
8 – 32 PNT800A-832R PNT600-02-832 Φ4.3 PNT600-01-832 8 – 32
10 – 24 PNT800A-1024R PNT600-02-5 Φ5.1 PNT600-01-1024 10 – 24
10 – 24 PNT800A-1032R PNT600-02-5 Φ5.1 PNT600-01-1032 10 – 32
¼ - 20 PNT800A-420R PNT600-02-420 Φ6.5 PNT600-01-420 ¼ - 20
5/16 – 18 PNT800A-518R PNT600-02-8 Φ8.1 PNT600-01-518R 5/16 – 18
3/8 – 16 PNT800A-616R PNT600-02-10 Φ10.1 PNT600-01-616R 3/8 – 16
Piloted Nosepiece Mandrel
Thin Wall
TK, TL &
TH
POP NUT
Thread
size
POP NUT Tool
Part No.
Part No. I.D. Part No.
Thread
size
6 – 32 PNT800A-632P PNT600-02-3P Φ3.6 PNT600-01-632 6 – 32
8 – 32 PNT800A-832P PNT600-02-4P Φ4.3 PNT600-01-832 8 – 32
10 – 24 PNT800A-1024P PNT600-02-5P Φ5.1 PNT600-01-1024 10 – 24
10 – 24 PNT800A-1032P PNT600-02-5P Φ5.1 PNT600-01-1032 10 – 32
¼ - 20 PNT800A-420P PNT600-02-420P Φ6.5 PNT600-01-420 ¼ - 20
5/16 – 18 PNT800A-518P PNT600-02-8P Φ8.1 PNT600-01-518 5/16 – 18
3/8 – 16 PNT800A-616P PNT600-02-10P Φ10.1 PNT600-01-616 3/8 – 16
M4×0.7 PNT800A-4P PNT600-02-4P Φ4.3 PNT600-01-4P M4×0.7
M5×0.8 PNT800A-5P PNT600-02-5P Φ5.1 PNT600-01-5P M5×0.8
M6×1.0 PNT800A-6P PNT600-02-6P Φ6.1 PNT600-01-6P M6×1.0
M8×1.25 PNT800A-8P PNT600-02-8P Φ8.1 PNT600-01-8P M8×1.25
M10×1.5 PNT800A-10P PNT600-02-10P Φ10.1 PNT600-01-10P M10×1.5
* Refer to the Maintenance and Testing section for details of Nosepiece and Mandrel replacement.
I.D.Thread size M8×1.0
I.D.Thread size M8×1.0

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 5
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 can 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.

Page 6 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Specifications
Table 3-1
Hydraulic oil
Use only Emhart Teknologies specified hydraulic oils as shown in Tabel 3-2.
Use of any other oil could reduce the tool performace or even damage the tool..
Table 3-2 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)
Feature Specification
Weight 1.68 kg (3.7 lbs)
Overall length 288 mm (11.3 in)
Overall height 263 mm (10.4 in)
Tool Stroke 1.3 - 6.3 mm (0.05 - 0.248 in)
Pulling Force 23.4 kN @ 5.0 bar ( 5260 lbf @ 72.5 psi)
Compressed air pressure required 0.5 - 0.6MPa (5 - 6 bar)
(72.5 - 87 psi)
Hydraulic Oil See Table 3-2 Specified Hydraulic Oils
Setting capacity See table 2-2
Tool Noise Level 72.7 dB(A)
Tool Vibration Level 0.92 m/s2/ 2.5 m/s2> 24hrs (EAV)
Figure 3-1

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 7
Tool Parts
Packaged Accessories
Part No. Item Qty
PNT800A-T PNT800A 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
FG2245 Operating Instructions 1
FG2244 Maintenance Manual 1
FG2222 Warranty Card 1
Air Chamber
Lock nut
Stroke Control
knob
Swivel fitting
(NPT 1/4)
Front case
Rear case
Mandrel
Nosepiece / Anvil
Nose Housing
Trigger
Handle
Fill screw
Coupler
（Plug）
Not included
Hose
Coupler
（Socket）
Exhaust holes
Exhaust holes

Page 8 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Tool Set Up
1. Check that the correct Nosepiece and Mandrel are fitted for the POP Nut.
Adjust the protruding length of the Mandrel. (Refer to “Maintenance and Testing”
section B).
2. The thread type of the compressed air supply coupling is NPT 1/4.
Connect a joint or coupler of thread type NPT 1/4 to supply compressed air.
(The Coupler and Joint are not provided.)
3. An air filter, regulator and lubricator should be fitted in the air line between the
compressor and the tool, within 3m (6 ft) of the tool. Adjust the supply pressure and
the drip volume of the lubricator oil.
•Compressed air pressure: 0.5-0.6 MPa. (72.5-87 psi)
•Oil drip volume from the lubricator: 1-2 drops/ 20 nuts fastened
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 a hose manufacturer's catalog.
Coupler (Plug)
Thread size NPT 1/4
Regulator
I.D. 6.5mm
(
1/4”
)
Min.
Not attached
Hose
Compressor
Air filter
Lubricator
Figure 4-1
Cou
p
le
r
(
Socket
)
3m
(
6ft
)
Max.

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 9
Figure 4-3
Figure 5-1
Work piece thickness
Maximum stroke (ＳMax )
Lock screw
(Never Loosen)
Lock screw
(Use 1.5mm hex)
Edge of control nut
Scale Control knob
Control nut
Figure 5-2
Stroke Adjustment
•Adjust the stroke length according to POP Nut size and the thickness of work piece.
•Make sure the tool has a consistent and adequate air supply.
•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)]
PROCEDURE
1. Determine required stroke
Find Maximum Stroke (S max), Minimum Stroke (S min)
and Stroke (E), based on the POP Nut and work piece
thickness from Table 5-5 "POP Nut Stroke Formulas”
and Table 5-6 “S max vs. t Graph.”
Example:
POP Nut: SPH625
Work piece thickness: 1.5mm
S max = 3.4 from formula or graph
S min = 3.0 (S max −0.4.) from formula
E = 3.6 (S max + 0.2) from formula
Proper stroke: 3.0 ~ 3.4 (S min ~ S max)
2. Stroke Adjustment
a) Loosen the M3 lock screw on the control
nut using a 1.5mm hexagonal wrench. Adjust
stroke by turning control knob clockwise to
decrease and anti-clockwise to increase stroke.
Stroke, E is indicated by the right edge of
control nut. Tighten the lock screw (Figure 5-2).
Note: Never loosen the lock screw on the
control knob, as this will disturb the stroke.
b) Set a POP Nut and measure the stroke
with calipers etc. to check the stroke setting
‘E’.
Re-adjust the stroke according to (a) so that
the stroke is E ± 0.1mm. (Figure 5-3).
Note: Using the control knob, adjustments equal to
0.2mm per quarter turn can be made.
c) Set a POP Nut using work piece or the test piece,
and check that the stroke is between S min and S max.
Re-adjust the stroke as necessary. (Figure 5-4)
Stroke S min ~ S max.
Stroke ‘E’
Figure 5-4
Figure 5-3

Page 10 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
3. Confirm the Stroke
Confirm stroke ( S max, S min, E) corresponding to the POP Nut and the work piece thickness
used.
Table 5-5 POP NUT™ Stroke Formulas - Thick Wall Only
*Thread size Maximum stroke
S max
Minimum stroke
S min
Stroke without
work piece
E
M3×0.5 1.2 + (N −t) mm S max −0.2 S max +0.1
M4×0.7 1.6 + (N −t) mm S max −0.3 S max + 0.1
M5×0.8 2.0 + (N −t) mm S max −0.3 S max +0.1
M6×1.0 2.4 + (N −t) mm S max −0.4 S max + 0.2
M8×1.25RLT *2.4 + (N −t) mm S max −0.4 S max +0.2
M8×1.25 2.8 + (N −t) mm S max −0.4 S max +0.2
M10×1.5 3.0 + (N −t) mm S max −0.4 S max +0.2
(*) M8×1.25RLT shows M8 steel knurled types.
M4, M5 and M6 steel knurled types have the same stroke as standard types.
Table 5-6 Ｓmax vs. t (Maximum stroke - Work piece thickness) graph
Thick wall POP Nuts
Where:
t：workpiece thickness
Ｎ: 1/10 of the last
two digit of the part
number
(Example)
625：25/10=2.5
Use the formula of stroke for
POP Nuts that are not
indicated in S max −t graph.
Example:
POP NUT No.
６２５
Maximum
thickness: 2.5mm
Thread size: M6×1.0
Work piece thickness
Maximum stroke
(
S max
)