TKR Group PNP 90 UN 2.0 User manual

Pneumatic, hydraulic
Universal Riveting Tool
PNP 90 UN 2.0
Instruction manual
Translation of the original instruction manual

2
Accessories and spare parts:
www.tkr-powertools.com
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 Hose package 10
3. Technical Data Hydraulic Actuator HP 35 UN 11
4. Technical Data Rivet Clamp 12
5. Technical Data Riveting Tool Kit RIVKIT UN 2.0 14
1. Startup 15
2. Riveting Tool Preparation and Connection of the Hydraulic Actuator 16
3. Connecting the hydraulic actuator to the hose 18
3. Safe Set-Up and Positioning of Equipment 19
4. Connecting the Tool to the Hydraulic Actuator 20
5. Riveting Tool Kit RIVKIT UN 2.0 – Fitting and Intended Use 21
1. Pressing out Rivets 22
2. Punching and Calibration of Holes for Flow Form Rivets 23
3. Setting of Flow Form Rivets 24
4. Installation of Semi-Tubular Punch Rivets 25
5 Checking Riveting Results 26
6. Cleaning the Riveting Tools 26
7. Completing an Operation and Riveting Tool Storage 27
1. Hydraulic pump maintenance 28
2. Replacement Part List 30
3. Troubleshooting 32
4. Disposal 33
5. Declaration of Conformity 34
1.
2.
3.
4.
5.
6.

3
1.1 Information regarding this manual
Observe
Instruction manual
Observe
General instructions
Wear face mask
Wear gloves
1.2 Explanation of symbols
Some sections of this instruction manual use internationally known 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 hydrauli-
cally-driven riveting tools must be protected. If desired,
training 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 techno-
logy. To ensure the functionality of the equipment, it
must be operated in a proper and safe manner.
Read the 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 manufac-
turer 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 main-
tenance process is laid out in the instruction manual.

1.3.1
A
B
C
D
F
B
4
AType designation
BSerial number
CManufacturer‘s designati-
on, 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 PNP 90 UN 2.0
was specially developed for all common riveting opera-
tions in thin sheet metal structures.
The equipment‘s universal technology enables adap-
tion of various attachments for different applications.
The basic tool kit comprises the pneumo-hydraulic
pressure intensifier PNP 90 and a hydraulic actuator
with hose assembly. 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 pressu-
re intensifier with a pressure ratio of 1:100. This means
that a hydraulic output pressure of 600 bar is gene-
rated with an input air pressure of 6 bar. When the
equipment‘s preset final pressure is reached, the pump
stops automatically 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 depressurized.
The two pneumatic control lines are also connected
to the pump. Make sure that the black and the blue
hoses are inserted in the couplings with the relevant
markings.
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 valve
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 deacti-
vated and the hydraulic plunger retracts to its original
position.

2.2.2
2.2.1
2.2.3
5
2.2 Scope of Supply and Accessories
Scope of supply complete kit PNP 90 UN 2.0
Art.-No. WZS-TKR-00000050
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
Owner‘s Manual
Accessories (not part of the complete kit)
1x Rivet clamp NB 115, Art.-No. WZS-TKR-00000027
1x Rivet clamp NB 230, Art.-No. WZS-TKR-00000026
1x Pop rivet adaptor RIVPULL 2.0**
1x Oval hole punch tool PUNCH-OV**
** in preparation
WZS-TKR-00000027WZS-TKR-00000050
WZS-TKR-00000026
Technical Specifications
Permissible hydraulic oil
Filling capacity 280 ccm/9,86 fl oz
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
Max. air pressure 6 bar / 87 psi
Compressed air Quality class 2 as per ISO 8573-1
Ambient temperature 5–50 °C / 41 –122 °F
Prescribed safety clothing Protective gloves, face mask
Noise emissions level LPAI < 75 db(A)
Vibration emissions level a < 2,5 m/s²

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 accident prevention.
Do not use any hoses or fittings that are not
permitted for the equipment's operating
pressure.
Because metallic parts can break up and
fly off with high energy if the tool is faulty
or operated incorrectly, protective gloves
and a face mask must strictly be worn for all
applications of the equipment.
As a result, there is a risk of severe physical
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 (41°F) and up to a
maximum of 50°C (122°F).
The tool must never be used in potentially
explosive areas.

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 pre-
vents people from tripping over them. Cor-
rectly route 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 physi-
cal injury!
Max. air pressure
Make sure that the maximum permissible
operating air pressure of 6 bar / 87 psi is never
exceeded. Check the setting of the pressure
regulating valve before each riveting opera-
tion!
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 da-
mage or injury caused by improper repair or
use of replacement parts made by other ma-
nufacturers.
Incorrect usage of the riveting tool that leads
to equipment damage invalidates the warran-
ty.
Declaration of Conformity
Riveting tool PNP 90 UN 2.0 has been tested
and manufactured in accordance with Europe-
an 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

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 oil or in the control air can cause
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 regular oil change (see 2.2 for permissible
oils).
All other necessary maintenance work and/
or repairs should be performed by the ma-
nufacturer 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 instruc-
tion manual.
Maintenance and repair work not covered
in this instruction manual may only be per-
formed by professionals with proper training
by TKR. For further information on servicing
and training, please contact us at our Service
address:
TKR Spezialwerkzeuge GmbH
Service
Am Waldesrand 9–11
D-58285 Gevelsberg (Germany)
Phone [phone]
Fax [phone]
Email [e-mail]
Accessories and spare parts:
www.tkr-powertools.com

9
Stamping and riveting tools from TKR Spezialwerkzeuge GmbH come with a
12-month warranty against material and manufacturing defects.
This does not cover wearing parts (rivet mandrels, rivet dies, spacing bolts and spa-
cing sleeves) or hydraulic oil.
The warranty period begins on the date of delivery, as specified on the invoice or
delivery note.
The warranty is valid for the user/customer provided that the tool is obtained from
an authorized 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 Spezialwerkzeuge GmbH will only repair or re-
place faulty parts at its own discretion.
Your supplier and service partner:
TKR Spezialwerkzeuge GmbH
Service
Am Waldesrand 9–11
D-58285 Gevelsberg (Germany)
Phone [phone]
Fax [phone]
Email [e-mail]
Accessories and spare parts:
www.tkr-powertools.com
2.6 Warranty

3.2.1
330
213
230
330
213
230
330
213
230
3 .1.1
3.1.3
3.1.2
10
3.1 Technical Data Pump PNP 90 UN 2.0
Length
Width
Height (incl. handle)
Weight
Max. input pressure
Max. operating pressure
Pump PNP 90 UN 2.0
330 mm
230 mm
213 mm
7.665 kg
6 bar
600 bar
365 mm
ca. 20 mm
1,100 kg
Hose length
Hose Ø
Weight
Hose package
3.2 Technical Data Hose package

267
117 50
267
117 50
267
117 50
3.3.1 3.3.2
3.3.3
11
Length
Width
Height (incl. handle)
Weight
Max. operating pressure
Travel
Hydraulic actuator HP 35 UN
Length and weight without hoses
267 mm
50 mm
117 mm
2.310 kg
600 bar
15 mm
3.3 Technical Data Hydraulic Actuator HP 35 UN

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

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
Rivet clamp NB 230
Rivet clamp NB 401Rivet clamp NB 115 Rivet clamp NB 230
Technical data
*Length and weight without hoses 1Included in the basic kit
Rivet clamp NB 401Rivet clamp NB 115 Rivet clamp NB 230
Article number 05-00000026 WZS-TKR-00000027 WZS-TKR-00000026
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

3.5.1
A
C
E
G
I
L
K
H
F
D
B
M
N
14
3.5 Technical Data, Riveting Tool Kit RIVKIT UN 2.0
Riveting Tool Kit RIVKIT UN 2.0
WZS-TKR-00000024
Kit number Item/Description/Article number Item/Description/Article number
Kit: BGR-TKR-
00000024
ASetting head, 3 mm
BGR-TKR-00000244
BClosing head, 3 mm
01-00000707
Kit: BGR-TKR-
00000023
CSetting head, 5 mm
BGR-TKR-00000245
DClosing head, 5 mm
01-00000706
Kit: BGR-TKR-
00000048
ESetting head,
flow form rivet,
Marked with 3 rings
01-00000917
FClosing head, flow form rivet
Marked with 3 rings
01-00000918
Kit: BGR-TKR-
00000098
GPunch and calibration
mandrel,
Marked with 2 rings
01-00000922
HPunch and calibration die
Marked with 2 rings
01-00000923
Kit: BGR-TKR-
00000128
IExtraction mandrel
Marked with 1 ring
01-00000788
KExtraction die
Marked with 1 ring
01-00000784
LReplacement elastomer
rings
06-00000112
MSet of fitting spanners
BGR-TKR-00000239
Kit: BGR-TKR
00000025
NSpacing adaptor composed of:
1Bushing, 01-00000744
2Spacing bolt 01-00000704
3Spacing sleeve 01-00000705

4 .1.1
4.1.44.1.3
15
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
fitted. 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 Start-up
4.1.2
R1/4“

4.2.1 4.2.2
4.2.3 4.2.4
16
4.2 Riveting Tool Preparation and
Hydraulic Actuator Connection
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 dama-
ge.
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

4.2.84.2.7
17
4.2 Riveting Tool Preparation and
Hydraulic Actuator Connection
4.2.8
Never use pressure over the permitted
value of 6 bar or 87 psi. This could cause
equipment damage or even physical inju-
ry.
4.2.7
Connect compressed air to the pressure regulating val-
ve and set the pressure.
max. 6 bar / 87 psi

4.3.4
4.3.1
4.3.3
4.3.2
4.3.64.3.5
18
4.3 Connecting the hydraulic actuator to the hose
4.3.1/4.3.2
The hydraulic actuator connections and the two hose pack-
age connections are fitted with caps. Remove the closing
caps from the corresponding couplings.
4.3.3/4.3.4
Connect the hydraulic actuator with the hose by pulling
the quick coupling rearwards and holding it while inserting.
When the quick coupling is released it will audibly engage.
4.3.5/4.3.6
When connecting the pneumatic control hoses, make sure
that the blue, silver and black hose are each connected to
the coupling with the same colour marking. The pneumatic
hoses must be inserted right up to the stop.

7
3
4.4.1
4.4.2
4.4.3
19
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.
4.4 Safe Set-Up and Positioning of Equipment

4.5.1 4.5.2
4.5.3
4.5.5
4.5.4
20
4.5 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 in 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.