Problem

• Lack of air pressure to the motor.
   

• The mandrel is bent and/or jammed in the prewinder threads.
    
   

• The mandrel is jammed in the adapter drive sleeve.

• Check air supply, regulator, and hoses.
   
   

• Disassemble the front end assembly from the adapter.  Screw the mandrel all the way through the prewinder until it disengages from the prewinder threads and floats freely, prior to tightening the retainer nut.  Replace mandrel if it is bent.
   

• Make sure there is a plastic cushion in the drive sleeve.  Add a second cushion if necessary to prevent the mandrel from jamming when the air motor reverses.

• Worn tip on mandrel, and/or worn threads on prewinder.
   
   

• Tapped holes out of specification.

• Insert should travel freely through the prewinder.  Lubricate moving parts (moly-disulphide grease or equivalent) and threads on mandrel and prewinder.  Replace worn parts if necessary.
   

• Gage tapped holes using an STI thread plug gage, and check minor diameter.  Make sure the hole was countersunk (before tapping).  Correct out of spec conditions.  Ref. MS33537 or KFS catalog.

• The mandrel is not picking up the rear threads of the prewinder when the air motor reverses.

• Hold the tool (prewinder) tip against the work surface as the mandrel is reversing.  This allows the mandrel to engage with the rear prewinder threads.  Do not pull the mandrel away from the work surface too quickly.

• Using the wrong spacer on the mandrel.
   

• Countersink is out of specification or is inconsistent from hole to hole.
   

• Lack of shim washers.
    

• Spacer is too thick.

• Check for correct spacer to correspond with the insert length.  Change if required.
   
  

• Check countersink diameter and angle per MS33537, or KFS catalog.  Make corrections as required.
   
   

• Add the shim washers that come with the front end assembly over the mandrel to decrease the installation depth as required.
   

• The spacer can be machined down to increase the installation depth.

• Excessive air pressure.
   
   

• Worn prewinder threads.
    

• Misalignment.
   
   

• Tapped holes out of specification.

• Reduce air pressure to the lowest pressure that will install the insert.  The PSI printed on the prewinder is a reference value, and is the absolute maximum pressure that should be used.
   

• Replace Prewinder.
   
   

• Check for correct alignment with the axis of the tapped hole.  This applies if the radial arm tool holder is used, or if the air tool is hand-held.
   

• Gage tapped holes using an STI thread plug gage, and check minor diameter.  Make sure the hole was countersunk (before tapping). Ref. MS33537, or KFS catalog.  Correct out of spec conditions.

• Low air pressure.  No  lubrication.  Dirty air supply.
   
    
    

• Air motor is worn or damaged.
   
   
   

• Front end assembly components are binding or are damaged.

• The air motor must be used with a filter-lubricator-regulator.  Check air pressure on regulator with PSI imprinted on the front end assembly.  Make sure the strainer is in place at the hose connection fitting on the back of the air motor.
   

• Return air motor to Kato authorized distributor for repair estimate.  Or, call KFS directly for location of nearest repair center.  Air motor is NOT user serviceable.  Do not attempt to disassemble the air motor.
   

• Disassemble front end assembly.  Lubricate all moving parts, including adapter keyway.  Make sure all parts turn freely.  Replace worn or broken components.

• Pawl is worn or broken.
   

• Mandrel threads are worn.
   

• Pawl does not move freely in mandrel slot.
   

• Missing pawl spring.

• Replace worn pawl with new one.
   
   

• Replace mandrel assembly with new one.
   
   

• Make sure slot is free of debris, and pawl moves freely.
   
   

• Check for missing spring.  Disassemble mandrel and replace spring.

• Worn or stripped rear threads in the prewinder.
   

• Mandrel not bottoming out on cushion in adapter sleeve.

• Replace prewinder.
   
   
   

• Add an additional plastic cushion to the bottom of the drive sleeve in the adapter.

• Broken or worn pin, or key on the back of the mandrel, or worn mandrel clutch assembly.

• Replace mandrel assembly.  On telescoping type mandrels, replacement of the pin only may correct the problem if the key is still intact.

• Failure to use the Air Motor Clutch Drive.
   
   
   

• Excessive air pressure.
   
   

• Misalignment.
   
   
   

• Operator error.

• The Clutch Drive must be used with 2-56 and 4-40 size Tangless front end assemblies.  KFS will not warrant the mandrels and pawls in these sizes without the use of the clutch drive.  KFS also recommends the clutch drive for all Tangless sizes up to ¼ inch (M6) to prevent breakage, and to prolong tool life.
   

• Check pressure on filter-lubricator-regulator gage vs. maximum PSI imprinted on prewinder.  Use the lowest air pressure that will install the insert.
   

• Make sure tool is aligned with the axis of the tapped hole.  Allow the tool to float relative to the work surface.  This will allow the insert to guide itself into the tapped hole.
   

• Refer to instructions included with the air motor and front end assembly.  Contact the Kato Tech Group by phone, or at techgroup@katonet.com 

• Hook (tip) of pawl is preventing the mandrel from engaging the prewinder threads.
   

• Worn or broken mandrel, or prewinder threads.

• Press on the pawl to retract the pawl tip and thread the mandrel into the prewinder.
    
   
   
   

• Replace worn or broken components as required.