Hole preparation: 

A.     Tangless inserts require no special hole preparation.  They install into the same tapped holes (ref. NASM33537) as conventional tanged inserts. 

B.      Countersinks are required for smooth installation.  It is important to countersink before tapping to eliminate burrs that can prevent the inserts from entering the tapped hole. 

C.     Tapped hole dimensions can be found in military standard NASM33537, KATO CoilThread® Tangless® and tanged inserts & tools catalog, or at our web-site www.katonet.com.  Finished threads must be capable of accepting the appropriate size and class of fit “go” thread plug gage for the full thread depth to accommodate the length of the insert to be installed.  The minor diameter must meet the requirements of NASM33537.  Tapped holes must be free of foreign objects such as dirt, chips and other debris. 

D.     If supplementary finishes such as plating, anodize, irridite, etc. Are used, the tapped holes must be capable of meeting the gaging requirements of paragraph c after the finish has been applied.  If zinc chromate primer is used, it should be thinned and applied sparingly to the tapped hole.  The inserts should be installed while the primer is still wet.  Care should be taken to prevent the installation tool from becoming clogged with primer.  It is recommended that the tip of the tool be dipped in the appropriate solvent or thinner regularly (approximately every 10 inserts) during the installation process, or as required. 

Installation procedures: 

A.     The installation and removal mandrels can be used either manually, or with the KATO electric power tool (CT5405 & CT5406).   For hand installation, the mandrel is used with the handle that is provided with the mandrel assembly.  For power installation, the mandrel is used with the KATO Electric Power Tool. 

B.      Insert length and depth adjustment:  using the two wrenches provided, loosen the lock nut and adjusting sleeve on the mandrel.  Screw the insert to be installed on to the mandrel until the pawl engages the insert driving notch.  Turn the adjusting sleeve until the plastic tip is almost touching the insert, leaving enough of a space to allow the insert to be installed below the top surface of the work-piece. 

Insert installation:  Tangless inserts are bi-directional, there is no need to orient the inserts prior to installation into the tapped holes.

Bulk inserts:  Screw the insert on to the mandrel approximately two full turns being careful not to cross-thread the insert.  Do not screw the entire length on to the mandrel.

Strip-feed inserts:  KATO does not recommend using strip-feed inserts with the electric tools.  For customers that must use strip feed inserts with the electric tool the following procedure is strongly recommended for fast and easy installation.

·         Cut the strop into one foot lengths for easier handling.

·         Hold the strip-feed in one hand above or near the work piece.  Hold the electric tool driver in the other hand.

·         Actuate the driver by depressing the trigger and engage the insert with the rotating mandrel.

·         While continuing to depress the trigger, pull the insert out of the plastic strip.

Procedure:  position insert and mandrels over the hole directly on the work-piece.  Straight alignment will provide for smooth installation and longer tool life.  Rotate the hand tool clockwise or depress the power tool trigger allowing the insert to seek out and engage the tapped thread.  Do not apply any downward force or try to force the insert into the hole.  Screw the insert into the tapped hole until the plastic tip contacts the work-piece.  Remove the hand tool from the installed insert by rotating it counterclockwise.  The electric tool reverses automatically.  The installed insert is complete.  There are no tangs to break-off, remove or loose! 

D.     When using the KATO electric tool, be sure to start with lowest torque setting and increase as required, to reach the minimum torque level that will install the insert.  For sizes 2-56 and 4-40 set the transformer power level to low, you may use the low or high setting for sizes 6-32 and up. Using the low setting will provide for increased tool life particularly on the smaller sizes.  The tool can be held or mounted on the KATO radial arm tool holder ( part number CT21042).  You may also purchase a KATO electric tool adapter for the KATO, or HeliCoil radial arm (part number CT21044A).

Insert removal:  

If necessary, installed KATO tangless inserts can be easily removed without damaging the work-piece.  The KATO removal tool assembly (CT16002R & CT16003R series) can be used either manually, or with the KATO electric power tool (CT5405 & CT5406). 

A.     Hand tool:  screw the removal mandrel into the installed insert until you feel or hear a “click” ( approximately 2 to 3 turns when the removal pawl engages the top notch of the insert.  Reverse the mandrel rotation and back the insert out the tapped hole.  To remove the insert from the mandrel press the pawl hook release, and unscrew the insert. 

B.      Power tool:  drive the removal mandrel into the installed insert by pressing the trigger on the electric motor.  The mandrel will reverse direction automatically when the plastic tip contacts the work-piece.  Then, the removal pawl will engage the top notch of the insert and back it out of the tapped hole.  Remove the insert by pressing the pawl hook release and unscrewing the insert from the mandrel.

Tool maintenance: 

Installation and removal tools should be periodically inspected for breakage and wear.  Tools should be kept clean so that foreign objects and debris (ex. Chips, oils and dirt) will not clog the tool preventing operation of moving parts.  Operator misuse can contribute to premature breakage of the pawl or mandrel. 

Pawl replacement: 

Each mandrel assembly comes complete with an extra pawl, cross pin and spring.  Follow the  procedures below to replace a worn or broken pawl. 

1.      Loosen the lock nut with the wrenches provided.

2.      Remove the lock nut and adjusting sleeve from the mandrel.

3.      Push out the cross pin, be careful not to lose the pin.

4.      Remove the damaged pawl from the mandrel slot, be careful not to lose the spring.  (the spring goes in the hole closest to the cross pin)

5.      Insert the replacement pawl into the mandrel slot.

6.      Line up the holes and press in the cross pin.

7.      Check for spring action and free movement of the pawl in the mandrel slot.

8.      Thread the lock nut and adjusting sleeve back onto the mandrel.  

For additional assistance contact the KATO® Tech-Group at 757-873-8980, or e-mail us at tech-group@katonet.com. 

Protect Your Vision:  Wear safety glasses when using KATO® Inserts and Tools.