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NIPPON POP RIVETS AND FASTENERS PNT1000 Instruction Manual

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ＰＯＰ ＮＵＴ ＴＯＯＬ
ＰＮＴ１０００
INSTRUCTION MANUAL
The PNT1000 is solely for use with Pop Nuts.
Read this manual thoroughly before you start and use the PNT1000 according
to the instructions.
Store this manual where the person who uses the tool may refer to it easily.
NIPPON POP RIVETS AND FASTENERS LTD.

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Summary of Contents for NIPPON POP RIVETS AND FASTENERS PNT1000

  • Page 1 INSTRUCTION MANUAL The PNT1000 is solely for use with Pop Nuts. Read this manual thoroughly before you start and use the PNT1000 according to the instructions. Store this manual where the person who uses the tool may refer to it easily.

  • Page 2: Table Of Contents

    ･ ・ ･ ･ ７ ５．Precautions on use ･ ・ ･ ･ ６．Adjustment of each part ･ ・ ･ ･ ７．How to use the PNT1000 ８．Maintenance and testing ･ ・ ･ ･ ９．Troubleshooting ･ ・ ･ ･ 10．Parts List ･ ・ ･ ･...

  • Page 3: Safety Precautions

    Safety Precautions -Read all the safety precautions carefully before you use this tool and observe them carefully in practice. -The safety precautions are classified as follows: WARNING! Incorrect operation caused by failure to observe this type of precaution could cause death or serious injury. Caution! Incorrect operation caused by failure to observe this type of precaution could cause injury or physical damage.
  • Page 4 7. Make sure the compressed air supply couplings are secure. If the screw threads of the couplings do not match perfectly, or if they are not screwed in far enough, the hoses and couplers etc. could come off while the tool is in use, possibly causing accident or injury. *Refer to section one (p.4) for details of part names.
  • Page 5 8. This tool should be serviced by a qualified technician who has a full understanding of its functions and mechanisms. Even experienced technicians should refer to this instruction manual and proceed carefully as instructed. If this tool is serviced by someone who lacks the required level of knowledge and ability, performance could be reduced and malfunctions could result, leading to accident or injury.

  • Page 6: １．Part Names

    PNT1000 1. Part names Front case Base material Nose housing Rear case Nose piece Mandrel Lock nut Exhaust holes Flange Body Control knob POP Nut Trigger Handle Coupler Coupler （ Plug ） Socket （ ） Hose Exhaust Chamber Thread size...
  • Page 7 2. Outline The PNT1000 is a small, lightweight tool for fastening Pop Nuts. It is driven by compressed air. Table 2-1 lists the Pop Nuts can be fastened using this tool. The Nosepiece and Mandrel must be changed to fit some sizes of Pop Nut. (See table 2-2) Each part must be adjusted before operation.
  • Page 8 3. Specifications (Table 3-1) Specifications Model PNT1000 Weight 2.5kg Overall length 320mm Overall height 276mm Stroke 1~7.5mm Compressed air pressure req'd 0.5~0.6MPa Pop-Nut which may be fastened See table 2-2 (p.5) (73) (320) (39)

  • Page 9: ４．Preparations For Use

    4. Preparations for use (1) Insert the Coupler plug (diameter R 1/4) to the compressed air supply (R joint). (Refer to page 8 for details). (The coupler and joint are not provided.) (2) An air filter, regulator and lubricator should be fitted in the air line between the compressor and the tool, within 3m of the tool.
  • Page 10 Regulator Lubricator Air filter Compressor 3m Max Coupler(Plug) Coupler（Socket） Hose （ I.D.6.5mm Min ） Thread size R 1/4 Not attached...

  • Page 11: ５．Precautions On Use

    5. Precautions on use The following precautions must be observed to ensure that the performance and service life of this tool are maintained. (1) Use the correct compressed air pressure Use compressed air at a pressure in the range 0.5~0.6 MPa . WARNING! If the compressed air pressure used exceeds the range above, this tool will break down and accident or injury could result.
  • Page 12 (4) Adjustment of each part Adjust each part before fastening POP Nuts. ※Refer to section six (p.11) for detail of method. Improper adjustment may cause damage of the tool or trouble and injury for shot of damaged part. (5) Hydraulic oil Use the designated hydraulic oil.

  • Page 13: ６．Adjustment Of Each Part

    6. Adjustment of each part Before fastening Pop Nuts, adjust each part by following procedure. 6-1. Mandrel and nosepiece replacement and mandrel protrusion length adjustment Use the designated parts to match the Pop Nut you will be using. (See p.5 table 2-2) Replace any parts that become worn or damaged.
  • Page 14 (Ⅱ) Nose piece replacement, adjustment of the mandrel protrusion length ≪Procedure≫ (1) Detach the coupler to stop the supply of compressed air. (2) Use a 30mm and a 26mm spanner to loosen the lock nut and remove the nosepiece and the lock nut from the nose housing. (See Figure 6-3) (3) Screw the lock nut to the designated nosepiece, and screw it to the nose housing until it stops.
  • Page 15 Warning! Inproper adjustment may cause damage the tool and trouble or injury by shot of broken parts as well as decrease in the tool performance. (2) Rough adjustment of stroke (scale units: 1mm) ① Use the hexagonal 1.5mm wrench (provided) to loosen the lock screw on the control nut.
  • Page 16 (3) Fine adjustment of stroke ①Fasten a pop nut without placing it into any base material and use calipers etc. to measure the caulk stroke ‘m’. (See Figure 6-7) ②Loosen the lock screw and turn the control knob to tune in exactly by the calculated discrepancy in the caulk stroke.
  • Page 17 POP NUT t-m GRAPH (COMMON TO ALL POP NUT) (1) t−m GRAPH (2) General formula Set POP nut without material (This formula can be used for POP (workpiece) and measure caulked nuts that are not indicated in t-m length to make it coincide with the graph.) value in t-m graph.

  • Page 18: ７．How To Use The Pnt1000

    7. How to use the PNT1000 WARNING ●Read “ Safety Precautions” (See P.1, 2) thoroughly before you use this tool and be sure to observe the instructions. ●Before you start fastening POP Nuts with this tool, be sure to adjust each part according to the instructions.
  • Page 19 (2) Fastening and detachment Push the POP Nut perpendicularly into the hole in the base material and pull the trigger (Figure 7-2). Keep pulling the trigger throughout fastening and detachment. Otherwise, detachment cannot be completed. The POP Nut is fastened and the tool automatically switches to reverse rotation to detach from the POP Nut (Figure 7-3).
  • Page 20 (3) To stop the reverse rotation of mandrel. Release the trigger to stop the mandrel rotation (Figure 7-4). Trigger Release Figure 7-4 (4) Steps for when the POP Nut is not detached correctly (a) If the reverse rotation of the mandrel stops before the POP Nut is detached from the mandrel (if you released the trigger too early), pull the trigger while pressing the control knob.

  • Page 21: ８．Maintenance And Testing

    8. Maintenance and testing (Table 8-1) Item Frequency Purpose Page Cleaning and lubrication Every -To smooth POP Nut mounting. ｐ.20 of mandrel. -To prevent early worn out of after 20 ∼ the mandrel. 30pcs fastening Lubricant spray Every -To prevent early loss of the ｐ.20 rotating parts.
  • Page 22 8-1 Regular mandrel cleaning and lubricant -Clean and lubricate the mandrel after every 20~30 fastenings to keep smooth mounting of POP Nut and to prevent the early abrasion of mandrel. (See Figure 8-1 and 8-2.) ≪Procedure≫ (1) Brush and clean the metal fragments stuck to the mandrel by wire brush. (Figure 8-1) (2) Lubricate the mandrel with 1∼2 drop of turbine oil, or spindle oil, penetrative lubricate oil, etc.
  • Page 23 Mandrel ≪Procedure≫ (1) Detach the coupler to stop the Screw by hand supply of compressed air. (2) Screw a POP Nut into mandrel by hand and check if mounting is smooth. (3) Check by sight if there is no Check by sight damage or abrasion on mandrel to cause trouble.
  • Page 24 ≪Procedure≫ (1) Detach the coupler to stop the supply of compressed air. (2) Pour 2cc of turbine oil (ISO VG32) into to coupler plug. (3) After connect and supply compressed air, depress the trigger to stroke without nut and keep reverse action for 30sec (Figure 8-6). Turbine oil ISO VG32 plug...
  • Page 25 (5) Press the control knob and line up the projection on the control nut with the slit of mast housing, then turn the control knob to the left to release the connected part. (Figure 8-9). (6) Remove the control knob from the tool body. (Control knob is assembled with control nut and T-valve push rod.) (Figures 8-10) (7) Use the 1.5mm hexagonal wrench to loosen the lock screws of the control knob and the control nut, and separate them from the T-valve push rod.
  • Page 26 (12) Minimum stroke adjustment Use the control knob to match the stroke with the scale, adjusting the stroke to 1mm. ① Loosen the lock screw on the control knob (do not loosen the lock screw of the control nut), then turn the control knob to the left by the amount of the difference between the stroke and the minimum graduation (mm).
  • Page 27 ≪Procedure≫ (1) Detach the coupler to stop the supply of compressed air. (2) Set the position of the control nut to approximately 10mm. (Refer to "(2) Rough adjustment of caulk stroke" on p.13.) *The maximum stroke of the tool is 7.5mm. *If you do not set the control nut to around 10mm, the valve and control nut could break.
  • Page 28 (5) Pour the specified hydraulic oil (See Table 5-1 on p.10) into the hole in the handle that the ram placed (Figure 8-18). Pour the oil in until its surface is level with the backup ring (Figure 8-19). Back up ring Specified hydraulic oil Same level...

  • Page 29: ９．Troubleshooting

    9.Troubleshooting (If you cannot fix the tool after checking the content of this section, send it to your supplier or one of our offices for repair.) Problem Cause Action Cannot mount the 1. Inappropriate part -Change to the right parts for the Pop Pop Nut.
  • Page 30 Problem Cause Action The mandrel breaks 1. The mandrel has reached the -Replace the mandrel with a new one. or bends. end of its service life. (See p.11) Or POP nut thread 2. Attempted doulbe caulking of -Do not attempt doulbe caulking. (See is damaged.

  • Page 31: 10．Parts List

    PNT1000 PNT1000 Parts List Product name Product name Product No. Q'ty Product No. Q'ty PNT600-01-6 Mnadrel PNT1000-M6 PNT1000-22 End cap PNT600-01-8 PNT1000-M8 O-RING-SS045(1A) O-ring PNT1000-01-10 PNT1000-M10 PNT1000-23 HU/EC tube PNT1000-01-12 PNT1000-M12 PNT1000-24 End cap tube PNT1000-58 Mandrel adapter PNT1000-M6,M8 CAP-SW-M4-10...
  • Page 32 O-RING-SS085(1A) O-ring 117 PNT600-117 Front plate PNT600-60 O-ring S6-1A 118 PNT600-118 Ball bearing PNT1000-50A valve lower 119 PNT600-119 Spacer 104 PNT1000-52 Valve upper assembly 1set 120 PNT600-120 Sun gear PNT1000-51 Valve center 121 PNT600-121 Planet gear PNT1000-53 Valve upper 122 PNT600-122 Needle pin 2.5×7.8...

  • Page 33: 11．Cross-Sectional Diagram Of The Pnt1000

    PNT1000 １０−１．Cross-sectional diagram of the PNT1000 - ３１ -...
  • Page 34 PNT1000 １０−２．Exploded diagram of the compressed air motor - ３２ -...

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