Information regarding this manual Information Handling Legislation stipulates that workers handling hydrauli- All handling necessary to ensure correct operation is cally-driven riveting tools must be protected. If desired, described in the instruction manual. No work method training can be provided at TKR in Gevelsberg or on other than that expressly approved by the manufac- site at the customer.
Symbol to read the instruction manual 2.1 Operating principles The pneumatic/hydraulic universal tool PNP 90 UN 2.0 pump via a high-pressure hose. The hose is connected was specially developed for all common riveting opera- to the pump via a leak-free quick release coupling. The tions in thin sheet metal structures.
2.3 Safety instructions The hydraulic tool kit is strictly approved Because metallic parts can break up and only for the purposes intended by the fly off with high energy if the tool is faulty manufacturer. or operated incorrectly, protective gloves and a face mask must strictly be worn for all Only genuine accessories may be used.
Declaration of Conformity Make sure that the maximum permissible operating air pressure of 6 bar / 87 psi is never Riveting tool PNP 90 UN 2.0 has been tested exceeded. Check the setting of the pressure and manufactured in accordance with Europe- regulating valve before each riveting opera- an guidelines.
2.5 Maintenance The tool‘s hydraulic system, pneumatic control sys tems, hoses and couplings Oil that is not properly disposed of could must all be kept free of dirt and other harm the environment. contamination. Foreign bodies in the hy- draulic oil or in the control air can cause The user must only perform the maintenance the tool system to malfunction.
2.6 Warranty 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.
3.1 Technical Data Pump PNP 90 UN 2.0 3.1.1 3.1.2 Pump PNP 90 UN 2.0 3.1.3 Length 330 mm Width 230 mm Height (incl. handle) 213 mm Weight 7.665 kg Max. input pressure 6 bar Max. operating pressure 600 bar 3.2 Technical Data Hose package...
3.3 Technical Data Hydraulic Actuator HP 35 UN 3.3.1 3.3.2 Hydraulic actuator HP 35 UN 3.3.3 Length 267 mm Width 50 mm Height (incl. handle) 117 mm Weight 2.310 kg Max. operating pressure 600 bar Travel 15 mm Length and weight without hoses...
3.5 Technical Data, Riveting Tool Kit RIVKIT UN 2.0 3.5.1 WZS-TKR-00000024 Riveting Tool Kit RIVKIT UN 2.0 Kit number Item/Description/Article number Item/Description/Article number Kit: BGR-TKR- A Setting head, 3 mm B Closing head, 3 mm 00000024 BGR-TKR-00000244 01-00000707 Kit: BGR-TKR- C Setting head, 5 mm D Closing head, 5 mm 00000023...
4.1 Start-up 4.1.1 4.1.2 G1/4“ 4.1.3 4.1.4 R1/4“ 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.
4.2 Riveting Tool Preparation and Hydraulic Actuator Connection 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.5 Connect the pneumatic hoses. Make sure that the black hose is attached to the marked coupling. Before using the equipment, check the condition of the hydraulic actuator with add-on component and hoses.
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4.2 Riveting Tool Preparation and Hydraulic Actuator Connection 4.2.7 4.2.8 max. 6 bar / 87 psi 4.2.7 Connect compressed air to the pressure regulating val- ve and set the pressure. 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-...
4.3 Connecting the hydraulic actuator to the hose 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3. 1 /4.3.2 4.3.5/4.3.6 The hydraulic actuator connections and the two hose pack- When connecting the pneumatic control hoses, make sure age connections are fitted with caps. Remove the closing that the blue, silver and black hose are each connected to caps from the corresponding couplings.
4.4 Safe Set-Up and Positioning of Equipment 4.4.1 Ensure that the high-pressure pump is 4.4.2 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.
4.5 Connecting the Tool to the Hydraulic Actuator 4.5.1 4.5.2 4.4.1/4.4.2 4.5.3 4.5.4 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.
4.6 Riveting Tool Kit RIVKIT UN 2.0 – Mounting and Intended Use 4.6.1 4.6.2 Three rivet clamps are currently available for use 4.6.3 with the RIVKIT UN 2.0 riveting tool kit: Rivet clamp Art. No. Opening depth NB 40 05-00000026 up t o 40 mm NB 115 WZS-TKR-00000027...
5.1 Pressing out Rivets 5.1.2 01-00000788 5.1.3 01-00000784 5.1.1 5.1.4 5.1.5 5.1.6 Old or defective rivets often need to be removed from the sheet metal structure when repairing body panels. 5.1.1 – 5.1.6 Instead of drilling out the old rivets, they can be pressed out of the sheet metal structure using the extraction mandrel (item no.
5.2 Punching and Calibration of Holes for Flow Form Rivets 5.2.1 01-00000922 5.2.2 01-00000923 5.2.3 5.2.1 – 5.2.5 5.2.4 There is no need to drill holes in sheet joints when using flow form rivets. Punch (item no. 01-00000922) and punch die (item no. 01-00000923) (kit BGR- TKR-00000098) enable precise hole punching and simultaneous calibration of rivet holes.
5.3 Setting Flow Form Rivets 5.3.1 01-00000917 5.3.2 01-00000918 5.3.3 5.3.4 5.3.5 5.3.1, 5.3.2 5.3.6 The flow form rivets are installed using the die head (item no. 01-00000917) and corresponding closing head (item no. 01-00000918) (kit BGR-TKR-00000048) intended for this purpose. 5.3.3 It is important that the die head with the centering lug engages in the corresponding depression in the rivet.
5.4 Installation of Semi-Tubular Punch Rivets 5.4. 1 BGR-TKR-00000244 5.4.2 01-00000707 5.4.3 BGR-TKR-00000245 5.4.4 01-00000706 Ø 3 mm Ø 3 mm Ø 5 mm Ø 5 mm 5.4.5 5.4.6 5.4.1 – 5.4.4 5.4.7 Extra care must be taken to ensure that the rivets that are used are properly seated when installing semi- tubular punch rivets.
5.5 Checking Riveting Results 5.5.1 – 5.5.3 5.5.1 5.5.2 The results must be checked after the riveting opera- tion. If the installed rivet does not meet quality requi- rements, the reason for the fault must be determined. If the quality of the installed rivet is acceptable, the work process can be repeated.
5.7 Completing an Operation and Riveting Tool Storage 5.7.1 5.7.1 Always disconnect the compressed air sup- ply from the pump after riveting and during work interruptions. 5.7.2 Then disconnect the control hoses and seal the openings. Make sure that the disconnected hoses ne- ver make contact with the dirty floor or the ground.
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6.1.6 6.1.5 280 cm / 9,47 fl oz 6.1.2 – 6.1.4 Draining oil 6.1.7 Undo the sealing plug on the top of the pump and let the used hydraulic oil flow into a suitable container. 6.1.5, 6.1.6 Filling oil Fill with fresh oil that complies with the specifications. The nominal filling volume is around 280 cm /9,47 fl oz.
6.2 Replacement Part List Pos.-No. Art. No. Title HYW-TKR-00000010 PNP 90 pressure intensifier (pump) BGR-TKR-00000631 Hose package BGR-TKR-00000484 Hydraulic actuator HP 35 UN HAW-TKR-00000121 Ball lock pin 05-00000026 Rivet clamp NB 40 WZS-TKR-00000027 Rivet clamp NB 115 Rivet clamp NB 230 WZS-TKR-00000026 (composed of pos.
6.3 Troubleshooting Problem Cause Remedy Page No air connected Connect compressed air Control lines not connected or Connect control lines correctly and make sure incorrectly connected they are properly seated Insufficient air pressure Check air supply Pump does not Connect hydraulic hose as described in the Hydraulic hose not connected instruction manual Air pressure not correctly set...
6.4 Disposal Devices and machinery and componen- ts of devices and machinery must be dis- posed of in accordance with the laws, regulations and other stipulations of the country in which they are located. We recommend that disposal be underta- ken by licensed professional operators.
Person authorised to compile the technical documentation: Thorsten Weyland Tool type: Pneumatic/hydraulic stamping and riveting tool Type designation: PNP 90 UN 2.0 Developed and manufactured in accordance with the standards and guidelines listed below by TKR Spezialwerkzeuge GmbH Am Waldesrand 9-11...
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Am Waldesrand 9–11 D-58285 Gevelsberg (Germany) Phone +49 2332 66607-0 +49 2332 66607-941 Accessories and spare parts: Email info@tkrgroup.com Internet www.tkrgroup.com www.tkr-powertools.com...
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