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Summary of Contents for TKR Group PNP 90 SNW-RIV
- Page 1 Pneumatic, hydraulic stamping and riveting tool PNP 90 SNW-RIV Instruction manual 83 43 2 158 708, Translation of the original instructions...
- Page 2 All photos, drawings and other illustrations as well as the text and other content in this instruction manual are subject to the copyright of both the TKR Group and the author involved. Reproduction, processing or other use is permitted only with express written consent.
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Page 3: Table Of Contents
Information regarding this manual 2. Explanation of symbols 3. Labelling Operating principles 2. Accessories and specifications 3. Noise and vibration values for PNP 90 SNW-RIV 4. Safety instructions 5. Fundamentals of riveting tool handling 6. Maintenance Technical data - pump PNP 90 2. -
Page 4: Information Regarding This Manual
1.1 Information regarding this manual Information Legislation stipulates that workers handling hydraulically-driv- en riveting tools must be protected. If desired, training can be provided at TKR in Gevelsberg or on site at the customer. Technical In the interests of quality assurance, we reserve the unre- modifications stricted right to carry out technical modifications on the basis of further developments in technology and product improve-... -
Page 5: Explanation Of Symbols
1.2 Explanation of symbols In this instruction manual, some sections use internationally Follow all in- known warning symbols, warning symbols and general in- structions and structional symbols. safety rules The individual symbols are explained below. Observe the instruction TÜV certification manual Observe the general Please note the following. -
Page 6: Labelling
1.3 Labelling 1.3.1 Stamping A Name and riveting Serial number tool label Manufacturer’s details, date of manufacture D Maximum permissible operating pressure (oil) CE mark Symbol to read the instruction manual... -
Page 7: Operating Principles
2.1 Operating principles The pneumatically driven stamping and riveting tool, model Pump PNP 90 PNP90 SNW-RIV, is used to install rivets. This tool set is special- ly designed to rivet sheet metal for the automotive industry. Each tool set consists of a pneumatically-driven hydraulic pump as well as the rivet clamp with hydraulic cylinder and the appro- priate rivet mandrels and dies for the rivets in question. -
Page 8: Accessories And Specifications
2.2 Accessories and specifications Permissible In the repair manual from the manufacturer recommended rivet accessories rivets Permissible Filling capacity 280 ccm hydraulic oil Hydraulic oil brand as per DIN 51524 and ATF as per DIN 51562-1; viscosity approx. 68 mm²/s at 40°C Example: Shell Tellus TX 68, Dexron, Mercon, Hydroclear Max. -
Page 9: Safety Instructions
2.4 Safety instructions The stamping and riveting tool must only be used for rivet- Permissible ing with the approved accessory tools. Only use genuine rivet rivet accesso- mandrels and dies for the two rivet sizes. Note the information ries list on the packaging. Make sure that the riveting tool is problem-free and that it has Usage as all functionality necessary to ensure safe operation. -
Page 10: Fundamentals Of Riveting Tool Handling
Incorrect usage of the riveting tool that leads to equipment damage invalidates the warranty. Declaration of Riveting tool PNP 90 SNW-RIV has been tested and manu- Conformity factured in accordance with European guidelines. The Decla- Chapter 5.3 ration of Conformity has been included with this instruction manual. -
Page 11: Maintenance
2.6 Maintenance The tool’s hydraulic system, pneumatic control systems, Care and hoses and couplings must all be kept free of dirt and maintenance other contamination. Foreign bodies in the hydraulic fluid or in the control air will cause the tool system to malfunction. -
Page 12: Technical Data Pump Pnp
3.1 Technical Data Pump PNP 90 3.1.1 3.1.2 Length 330 mm 3.1.3 Width 230 mm Height (incl. handle) 213 mm Weight 7,665 kg Max. Input pressure 6 bar Max. Operating pressure 600 bar... -
Page 13: Technical Data Rivet Clamp Snw-Riv
3.2 Technical Data Rivet clamp SNW-RIV 3.2.1 3.2.2 Length 340 mm 3.2.3 Width 60 mm Height 275 mm Clamp opening 78 mm Opening depth 125 mm Stroke 25 mm Press force (6 bar) 55 kN Weight 5 kg Length and weight without hoses... -
Page 14: Initial Start-Up
4.1 Initial start-up 4. 1 . 1 4. 1 .2 G1/4“ The equipment is delivered from the factory without a com- pressed air connection. The pressure reducing valve has a con- nection thread of G1/4“ (internal thread). The pressure regulating valve is delivered with a cap fitted (Fig. 4.1.1). - Page 15 4. 1 .3 4. 1 .4 R1/4“ Use a compressed air connection with R1/4“ thread and seal (Fig. 4.1.3). Screw this onto the regulating valve (Fig. 4.1.4).
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Page 16: Riveting Tool Preparation And Connection
4.2 Riveting tool preparation and connection 4.2.1 4.2.2 4.2.3 4.2.4 Before using the equipment, check the condition of the riveting tool and the hoses. Risk of severe bodily injury if the pump or the rivet clamp is damaged. - Page 17 4.2.5 4.2.6 black blue Check the hoses and couplings for damage. Connect the high-pressure hose to the high-pressure pump with the quick release coupling. Make sure that the high-pres- sure coupling completely engages and locks (Fig. 4.2.4). Connect the pneumatic hoses. Make sure that the black hose is attached to the marked coupling (Fig.
- Page 18 4.2 Riveting tool preparation and connection 4.2.7 4.2.8 4.2.9 4.2.10 Insert the rivet mandrel and rivet die for 4.2.1 1 the planned riveting operation in the rivet clamp and screw them into place (Fig. 4.2.7 – 4.2.11). During the entire process, always make sure that the rivet mandrel and die are firmly seated.
- Page 19 4.2.12 4.2.13 Make sure that both the correct rivet 4.2.14 mandrel and the correct die are used. Elastomer ring, Wrench set, Check for the correct part numbers and 06-000001 12 BGR-TKR-00000239 designations (Fig. 4.2.14 / 4.2.15 / 4.2.16). Distance bolt, Set: 81 43 2 209 937* 1 = Bushing, 81 43 2 209 937 C 2 = Distance bolt, 81 43 2 209 937 B 3 = Spacer, 81 43 2 209 937 A...
- Page 20 4.2 Riveting tool preparation and connection 4.2. 1 7 4.2. 1 8 max. 6 bar / 87 PSI Connect compressed air to the pressure regulating valve and set the pressure (Fig. 4.2.16 / 4.2.17). Never use pressure over the permitted value of 6 bar or 87 PSI.
- Page 21 4.2.19 4.2.20 Make sure that the pump is standing on a non-slip surface and that the hoses are routed in a way that prevents them from being damaged or pinched. In addition, the hoses must be routed in a manner that prevents people from tripping over them (Fig.
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Page 22: Riveting Tool Operation
4.3 Riveting tool operation Only use tools and accessories that do 4.3.1 not show signs or wear or damage. It is particularly important for the rivet stamp and rivet die that they are prop- erly seated and show no signs of dam- age. - Page 23 4.3.4 4.3.5 When both control valves are operating, the riveting op- eration is started and the hydraulic plunger comes out and stamps the rivet into the sheet metal (Fig. 4.3.5). The rivet clamp can be pivoted 360° (Fig. 4.3.6). If the maximum press pressure is reached, the pressure indica- tor on the pivoting connection of the rivet clamp is activated.
- Page 24 4.3 Riveting tool operation 4.3.8 4.3.9 The results should be checked after the 4.3.10 riveting operation. If the installed rivet does not meet quality requirements, the reason for the fault must be deter- mined. If the quality of the installed rivet is ac- ceptable, the work process can be re- peated.
- Page 25 4.3.1 1 4.3.12 Upon completing riveting work, remove excess adhesive resi- due (only when using adhesive rivets) from all contaminated parts. Remove all relevant tool components (Fig. 4.3.11) and clean them with acetone. If adhesive residue is allowed to remain on the riveting equipment, it will eventually cause malfunction.
- Page 26 4.3 Riveting tool operation 4.3.13 4.3.14 After riveting or when taking a break from work, disconnect the compressed air supply from the pump (Fig. 4.3.13). Then disconnect the control hoses and seal the openings (Fig. 4.3.14). Make sure that the disconnected hoses never make contact with the dirty floor or the ground.
- Page 27 4.3.15 Before and after each operation, check the system for oil leaks (Fig. 4.3.15). An oil leak indicates a fault in the system. In such cases, interrupt work and locate the fault or send the equip- ment to an authorised dealer for repair.
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Page 28: Hydraulic Pump Maintenance (Oil Change)
4.4 Hydraulic pump maintenance 4.4.1 4.4.2 4.4.3 Draining oil 4.4.4 Undo the sealing plug on the top of the pump (Fig. 4.4.2 / 4.4.3) and let the used hydraulic fluid flow into a suitable container (Fig. 4.4.4). - Page 29 4.4.5 4.4.6 4.4.7 4.4.8 Filling oil Fill with fresh oil that complies with the specifications. Filling Main- capacity is normally approx. 280 ccm (Fig. 4.4.5). When filling, tenance the oil level should reach the filler neck, but the thread of the chapter 2.6 sealing plug must remain visible (Fig.
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Page 30: Riveting Tool Storage
4.5 Riveting tool storage 4.5.1 Only store the tool in the transport case designed for this purpose. Make sure that the hoses do not become kinked (Fig. 4.5.1)! Never transport the tool by the hos-... -
Page 32: Troubleshooting
5.1 Troubleshooting Problem Cause Remedy Page No air connected Connect compressed air Control lines not con- Connect control lines cor- nected or incorrectly rectly and make sure they connected are properly seated Insufficient air pressure Check air supply Pump does not run Connect hydraulic hose Hydraulic hose not as described in the... - Page 33 Problem Cause Remedy Page Check oil level and top Too little oil in the pump up if necessary The rivet plunger Hydraulic seal in the Repair through manu- travels too slowly or – pump is worn facturer not at all Defect valves in the Repair through manu- –...
- Page 34 5.2 Warranty Stamping and riveting tools from TKR Spezialwerkzeuge GmbH come with a 24-month warranty against material and manufacturing defects. This does not cover the wear parts (rivet mandrels, rivet dies, spacing bolts and spacing sleeves) or hydraulic oil. The warranty period begins on the date of delivery, as speci- fied on the invoice or delivery note.
- Page 35 EC Declaration of Conformity In accordance with EU Machinery Directive 2006/42/EC Manufacturer: TKR Spezialwerkzeuge GmbH Am Waldesrand 9–11 58285 Gevelsberg, Germany Contact: Thorsten Weyland, Technical director Technical documentation Tool type: Pneumatic/hydraulic stamping and riveting tool Type designation: PNP 90 SNW / RIV Has been developed and designed in accordance with the standards and guidelines specified below by...
- Page 36 TKR Group Am Waldesrand 9–11 D-58285 Gevelsberg (Germany) Phone +49 2332 66607-77 +49 2332 66607-51 E-mail info@tkrgroup.com Spare parts service: www.tkr-service.com Internet www.tkrgroup.com...
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