TKR Group PNP 90 UN 2.0 User manual

Pneumatic, hydraulic
Universal Riveting Tool
PNP 90 UN 2.0
Instruction manual
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 1 22.07.11 14:08

2
1. Information regarding this manual 3
2. Explanation of symbols 3
3. Designations 4
1. Operating principles 4
2. Scope of Supply and Accessories 5
3. Safety instructions 6
4. Principles for Handling the Tool Kit PNP 90 UN 2.0 7
5. Maintenance 8
6. Warranty 9
1. Technical Data Pump PNP 90 UN 2.0 10
2. Technical Data Hydraulic Actuator HP 35 UN 10
3. Technical Data Riveting Tool Kit RIVKIT UN 2.0 11
4. Technical Data Rivet Clamp 12
1. Startup 14
2. Riveting Tool Preparation and Connection of the Hydraulic Actuator 15
3. Safe Set-Up and Positioning of Equipment 17
4. Connecting the Tool to the Hydraulic Actuator 18
5. Riveting Tool Kit RIVKIT UN 2.0 – Fitting and Intended Use 19
1. Pressing out Rivets 20
2. Punching and Calibration of Holes for Flow Form Rivets 21
3. Setting of Flow Form Rivets 22
4. Installation of Semi-Tubular Punch Rivets 23
5 Checking Riveting Results 24
6. Cleaning the Riveting Tools 24
7. Completing an Operation and Riveting Tool Storage 25
1. Hydraulic pump maintenance 26
2. Replacement Part List 28
3. Troubleshooting 30
4. Declaration of Conformity 31
1.
2.
3.
4.
5.
6.
Accessories and spare parts:
www.tkr-powertools.com
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 2 22.07.11 14:08

3
1.1 Information regarding this manual
Observe
Instruction manual
Observe
General instructions
Wear face mask
Wear gloves
1.2 Explanation of symbols
In this instruction manual, some sections use internationally recognised warning symbols, warning
notes and general instructional symbols.
The individual symbols are explained below. Follow all instructions and safety rules.
Warning!
General source of danger
Warning!
Hand could become
trapped
Warning!
Fingers could become
trapped
Warning!
Danger of environmental
contamination
Warning!
System under pressure
Please note the
following!
Arrow to clarify compres-
sion
Arrow showing direction
For further information
see chapter...
Audibly engage
Information
Legislation stipulates that workers handling hydraulically-
driven riveting tools must be protected. If desired, trai-
ning can be provided at TKR in Gevelsberg or on site at
the customer.
State of the technology
This riveting tool represents state-of-the-art technology.
To ensure the functionality of the equipment, it must be
operated in a proper and safe manner.
Read instruction manual
Read the instruction manual carefully before using the
riveting tool.
Handling
All handling necessary to ensure correct operation is
described in the instruction manual. No work method
other than that expressly approved by the manufacturer
may be used.
Faults
In the event of a fault, the user or owner may only carry
out repair work for faults for which the relevant maintenance
process is laid out in the instruction manual.
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 3 22.07.11 14:08

1.3.1
A
E
B
C
D
F
4
AType designation
BSerial number
CManufacturer‘s designation,
production date
DMaximum permissible
operating pressure (oil)
ECE mark
FSymbol to read the
instruction manual
1.3 Designations
Designations on the stamping and riveting tool
2.1 Operating principles
The pneumatic/hydraulic universal tool PNP90-UN 2.0
was specially developed for all common riveting opera-
tions in thin sheet metal structures.
The equipment‘s universal technology enables adaption
of various attachments for different applications.
The basic tool kit comprises the pneumo-hydraulic pressure
intensifier PNP 90 and a hydraulic actuator with hose
package. The kit is completed by an NB 40 rivet clamp
and a fully equipped RIVKIT UN 2.0 riveting tool kit.
The hydraulic pump is a pneumatically driven pressure
intensifier with a pressure ratio of 1:100. This means that
hydraulic output pressure of 600 bars is generated with
input air pressure of 6 bars. When the equipment‘s pre-
set final pressure is reached, the pump stops automatical-
ly and keeps this pressure constant. The hydraulic pump
has a pneumatically controlled pressure relief valve.
The hydraulic actuator is connected to the hydraulic
pump via a high-pressure hose. The hose is connected
to the pump via a leak-free quick release coupling. The
coupling can only be connected to the equipment when
it is depressurised.
The two pneumatic control lines are also connected to
the pump. Make sure that the black and the blue hose
are inserted into the couplings with the relevant mar-
kings.
Compressed air can be connected to
the equipment as soon as the hydraulic
hose and the control lines are connected to
the pump.
The hydraulic actuator is equipped with a control val-
ve that activates pump operation. The operating lever
is equipped with a safety catch to prevent unintended
operation.
If the valve is activated, the pump begins to run and the
hydraulic plunger extends.
If the operating lever is released, the pump is deactivated
and the hydraulic plunger retracts to its original position.
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 4 22.07.11 14:08

5
2.2 Scope of Supply and Accessories
Scope of supply basic kit PNP 90 UN 2.0
1x Pressure intensifier PNP 90
1x Hydraulic actuator HP 35 UN
1x Rivet clamp NB 40
1x Riveting tool kit RIVKIT-UN 2.0
2x Locking bolts
1x Owner‘s Manual
Technical Specifications
Filling capacity 280 ccm
Branded hydraulic oils as per DIN 51524
ATF as per DIN 51562-1
Viscosity approx. 68 mm²/s at 40 °C,
Example: Shell Tellus TX 68, Dexron, Mercon, Hydroclear
6 bar / 87 psi
Quality class 2 as per ISO 8573-1
5–50 °C / 41 –122 °F
Protective gloves, face mask
LPAI < 75 db(A)
Permissible hydraulic oil
Max. air pressure
Compressed air
Ambient temperature
Prescribed safety clothing
Noise emissions level
The effective value of the acceleration assessed at the hydraulic tool measured in accordance with ISO/FDIS B662-
11 is < 2.5 m/s²
Accessories (not part of the basic kit)
1x Rivet clamp NB 115
1x Rivet clamp NB 230
1x Pop rivet adaptor RIVPULL 2.0**
1x Oval hole punch tool PUNCH-OV**
** in preparation
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 5 22.07.11 14:08

6
2.3 Safety instructions
The hydraulic tool kit is strictly approved only
for the purposes intended by the manufacturer.
Only genuine accessories may be used. Use
of non-genuine tools or accessories presents a
major safety hazard.
Ensure that only trained and instructed
personnel use the equipment!
Use of the equipment by personnel that have
not been trained and instructed is prohibited.
Ensure that the instruction manual is made
available to operating personnel.
Observe the applicable national regulations for
prevention of accidents.
Do not use any hoses or fittings that are not
permitted for the equipment's operating
pressure.
Protective gloves and a face mask must strictly
be worn for all applications of the equipment,
because metallic parts can break up and fly
off with high energy if the tool is faulty or
operated incorrectly.
As a result, there is a risk of severe bodily injury!
See also ANSI Z87.1-1989.
Never throw the tool or allow it to fall.
Never misuse the tool or lend it to untrained
personnel.
The tool must only be used in ambient
temperatures of above 5 °C and up to a
maximum of 50 °C.
The tool must never be used in potentially
explosive areas.
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 6 22.07.11 14:08

7
2.4 Principles for Handling
the PNP 90 UN 2.0 Tool Kit
Risk of injury
Route all supply lines in a manner that prevents
people from tripping over them. Correctly rou-
te and attach the compressed air hose. If a
compressed air hose whips around wildly, it
could cause severe physical injury.
Before starting work, check the preset air
pressure! Incorrectly set air pressure could
cause equipment damage or physical injury!
Max. air pressure
Make sure that the maximum permissible ope-
rating air pressure of 6 bar / 87 psi is never
exceeded. Check the setting of the pressure re-
gulating valve before each riveting operation!
Clean compressed air
Make sure that the pump is always supplied
with clean and dry compressed air. Moisture
and contamination could cause equipment
malfunction and/or damage. Only use com-
pressed air of quality class 2 as per ISO 8573-1.
Always disconnect the riveting tool from
pressure when leaving the work site!
Warranty
The manufacturer accepts no liability for damage
or injury caused by improper repair or use of re-
placement parts made by other manufacturers.
Incorrect usage of the riveting tool that leads
to equipment damage invalidates the warranty.
Declaration of Conformity
Riveting tool PNP 90 UN 2.0 has been tested
and manufactured in accordance with European
guidelines. The Declaration of Conformity has
been included with this instruction manual.
The compressed air supply must be dis-
connected from the equipment before
any adjustment or maintenance work is
performed.
6.4
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 7 22.07.11 14:08

8
2.5 Maintenance
The tool‘s hydraulic system, pneumatic
control systems, hoses and couplings
must all be kept free of dirt and other
contamination. Foreign bodies in the hy-
draulic fluid or in the control air can cau-
se the tool system to malfunction.
All maintenance and service work on the
stamping and riveting tool must only be
performed with the pump disconnected.
All maintenance and service work on the
pump must only be performed with the
air disconnected and the oil drained.
Normally, pump maintenance only entails a re-
gular oil change (see 2.2 for permissible oils).
All other necessary maintenance work and/or
repairs should be performed by the manufac-
turer or properly trained personnel.
With normal use of the pump, hydraulic oil
should be changed every 80 operating hours
or every 12 months. Make sure that used oil
is disposed of as required by national environ-
mental legislation.
6.1
Oil that is not properly disposed of could
harm the environment.
The user must only perform the maintenance
and repair measures outlined in this instruction
manual.
Maintenance and repair work not covered in
this instruction manual may only be performed
by professionals with proper training by TKR.
For further information on servicing and trai-
ning, please contact us at our Service address:
TKR Automotive GmbH
Am Waldesrand 9–11
D-58285 Gevelsberg (Germany)
Phone [phone]
Fax [phone]
Email [e-mail]
Internet www.tkrgroup.com
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 8 22.07.11 14:08

9
Stamping and riveting tools from TKR Automotive GmbH come with a 12-month war-
ranty against material and manufacturing defects.
This does not cover wearing parts (rivet mandrels, rivet dies, spacing bolts and spacing
sleeves) or hydraulic oil.
The warranty period begins on the date of delivery, as specified on the invoice or de-
livery note.
The warranty is valid for the user/customer provided that the tool is obtained from an
authorised sales outlet and is used as described in the instructions and for the purposes
for which it was designed.
The warranty becomes invalid if the tool is used for purposes other than those for
which it was designed.
In addition, the warranty becomes invalid if the tool is not used as described in the
instruction manual.
In the event of defect or fault, TKR Automotive GmbH shall only repair or replace faulty
parts at its own discretion.
Your supplier and service partner:
TKR Automotive GmbH
Am Waldesrand 9–11
D-58285 Gevelsberg (Germany)
Phone [phone]
Fax [phone]
Email [e-mail]
Internet www.tkrgroup.com
2.6 Warranty
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 9 22.07.11 14:08

104.7
246.5
50
104.7
246.5
50
104.7
246.5
50
3.2.1 3.2.2
3.2.3
330
213
230
330
213
230
330
213
230
3.1.1
3.1.3
3.1.2
10
246.5 mm
50 mm
104.7 mm
2 kg
600 bar
15 mm
Length
Width
Height (incl handle)
Weight
Max. operating pressure
Travel
Hydraulic actuator HP 35 UN
3.2 Technical Data Hydraulic Actuator HP 35 UN
3.1 Technical Data Pump PNP 90 UN 2.0
330 mm
230 mm
213 mm
8 kg
5.5 bar
550 bar
Length
Width
Height (incl handle)
Weight
Max. input pressure
Max. operating pressure
Pump PNP 90 UN 2.0
Length and weight without hoses
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 10 22.07.11 14:08

3.3.1
A
C
E
G
I
L
K
H
F
D
B
M
N
WZS-TKR-00000024
12
3
11
3.3 Technical Data Riveting Tool Kit RIVKIT UN 2.0
Kit number Item/Description/Article number Item/Description/Article number
Riveting Tool Kit RIVKIT UN 2.0
Kit: BGR-TKR- ASetting head, 3 mm rivet BClosing head, 3 mm rivet
00000024 BGR-TKR-00000244 01-00000707
Kit: BGR-TKR- CSetting head, 5 mm rivet DClosing head, 5 mm rivet
00000023 BGR-TKR-00000245 01-00000706
Kit: BGR-TKR- ESetting head, flow form rivet FClosing head, flow form rivet
00000048 Marked with 3 rings Marked with 3 rings
01-00000917 01-00000918
Kit: BGR-TKR- GPunch and calibration mandrel HPunch and calibration die
00000098 Marked with 2 rings Marked with 2 rings
01-00000922 01-00000923
Kit: BGR-TKR- IExtraction mandrel KExtraction die
00000128 Marked with 1 ring Marked with 1 ring
01-00000788 01-00000784
LReplacement elastomer rings MSet of fitting spanners
06-00000112
BGR-TKR-00000239
Kit: BGR-TKR NSpacing adaptor composed of:
00000025 1Bushing, 01-00000744
2Spacing bolt 01-00000704
3Spacing sleeve 01-00000705
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 11 22.07.11 14:09

106
158.8
80
45
25
106
158.8
80
45
25
106
158.8
80
45
25
3.4.1
3.4.3
3.4.2
213
220.3
44
80
140.2
25
213
220.3
44
80
140.2
25
213
220.3
44
80
140.2
25
3.4.4
3.4.6
3.4.5
12
Rivet clamp NB 40
3.4 Technical Data Rivet Clamp
Rivet clamp NB 115
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 12 22.07.11 14:09

140
364.1
347.2
44.5
30
140
364.1
347.2
44.5
30
140
364.1
347.2
44.5
30
3.4.7
3.4.9
3.4.8
13
Article number 05-00000026 05-00000031 05-00000027
Length* 106 mm 213 mm 364.1 mm
Width 45 mm 44 mm 44.5 mm
Height 158.8 mm 220.3 mm 347.9 mm
Clamp opening 80 mm 80 mm 140 mm
Opening depth 40 mm 115 mm 230 mm
Weight* 1.5 kg 3 kg 9.5 kg
Rivet clamp NB 230
Rivet clamp NB 401Rivet clamp NB 115 Rivet clamp NB 230
*Length and weight without hoses 1Included in the basic kit
Technical data
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 13 22.07.11 14:09

4.1.1
4.1.44.1.3
14
G1/4“
The equipment is supplied from the factory without a
compressed air connection. The pressure regulator has a
G1/4“ (internal thread) connection thread.
4.1.1/4.1.2
The pressure regulator is supplied with a closing cap fit-
ted. Remove the closing cap.
4.1.3/4.1.4
Use a compressed air connection with R1/4“ thread and
seal. Screw this into the regulator.
4.1 Startup
4.1.2
R1/4“
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 14 22.07.11 14:09

4.2.1 4.2.2
4.2.3 4.2.4
15
4.2 Riveting Tool Preparation and
Connection of the Hydraulic Actuator
Before using the equipment, check the
condition of the hydraulic actuator with
add-on component and hoses. Risk of
severe physical injury if the pump or the
rivet clamp is damaged.
Check the hoses and couplings for damage.
In the event of any noticeable damage,
the hydraulic components must be re-
placed. Damaged hoses or couplings
could cause severe injury!
Incorrectly attached hoses could come
loose and cause severe physical injury.
4.2.5
4.2.6
4.2.5
Connect the pneumatic hoses. Make sure that the black
hose is attached to the marked coupling.
black
blue
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 15 22.07.11 14:09

4.2.84.2.7 max. 6 bar / 87 psi
16
4.2 Riveting Tool Preparation and
Connection of the Hydraulic Actuator
4.2.8
Never use pressure over the permitted va-
lue of 6 bar or 87 psi. This could cause
damage to the equipment or even physical
injury.
4.2.7
Connect compressed air to the pressure regulating valve
and set the pressure.
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 16 22.07.11 14:09

7
3
4.3.1
4.3.2
4.3.3
17
4.3 Safe Set-Up and Positioning of Equipment
Ensure that the high-pressure pump is
always placed on a non-slip surface and
that the hoses are routed in a way that
prevents them from getting damaged
or pinched off. The hoses must also be
routed in a way that prevents people
from tripping over them.
Make sure that the pump and hydraulic
actuator are set up in a work area that
is free from heat sources (max. 50°C /
120°F), corrosive liquids, greases and
oils.
Before using the equipment, make sure
that the pump is standing on a secure
surface.
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 17 22.07.11 14:09

4.4.1 4.4.2
4.4.3
4.4.5
4.4.4
18
4.4 Connecting the Tool to the Hydraulic Actuator
Warning!
The mounting adaptor on the hydraulic
actuator must be clean and free from
damage!
The locking bolts must also be free from
contamination and damage.
The mounting hole in each tool must be
free from contamination and damage!
Warning!
Damaged or defective locking pins must
not be used!
4.4.1/4.4.2
Select tool and prepare locking pins. The tool is carefully
pushed onto the mounting adapter by the mounting
hole. The indexing pin in the mounting adaptor must
engage in the corresponding slots in the mounting hole.
4.4.3./4.4.4/4.4.5
The two locking pins are inserted into the locking holes
with the release button pressed.
The tool must be pressed gently in the direction of the
clamp while doing so. The pin must lock automatically
once inserted and must not fall out of the locking hole
by itself.
The tool is now ready for use.
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 18 22.07.11 14:09

4.5.1 4.5.2
4.5.3
4.5.4
19
4.5 Riveting Tool Kit RIVKIT UN 2.0 –
Fitting and Intended Use
Three rivet clamps are currently available for use
with the RIVKIT UN 2.0 riveting tool kit:
Rivet clamp Art. No.
Opening depth
NB 40105-00000026 up to 40 mm
NB 115 05-00000031 up to 115 mm
NB 230 05-00000027 230 mm
1Included in the basic kit
4.5.1/4.5.2
Screw the riveting tool needed for the working process
into a holder in the rivet clamp as required. Hand-tighten
the riveting head using the special spanners provided. Do
not use force. Counterhold the nut using a screwdriver
if necessary.
4.5.3/4.5.4
Screw the corresponding counterpart to the rivet insert
into the opposite side of the rivet clamp (plunger rod)
with the spacing bushing and bolt, and hand-tighten.
Do not use force!
Each time rivet inserts are to be fitted,
the bolt and die must be checked for a
correct match first!
Refer to the usage matrix in the RIVKIT
UN 2.0 case for details.
Check that the riveting heads are firmly
seated after each riveting operation. Rivet
inserts that have come loose present a
hazard and can lead to destruction of the
equipment.
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 19 22.07.11 14:09

5.1.2 01-00000788
5.1.4 5.1.5
5.1.6
5.1.1
7
5.1.3 01-00000784
20
5.1 Pressing out Rivets
Old or defective rivets often need to be removed from
the sheet metal structure when repairing body panels.
5.1.1 – 5.1.6
To avoid having to drill out these rivets, the olds rivet can
be pressed out of the sheet metal structure using the
extraction mandrel art. no. 01-00000788 and extraction
die art. no. 01-00000784 (kit BGR-TKR-00000128),
thereby minimising damage.
Anleitung Stanznietwerkzeug PNP_90_UN2.indd 20 22.07.11 14:09