KATO Air Tool and Components Troubleshooting Guide

Problem Cause Solution
Air Motor does not run when lever is pressed. Lack of air pressure to the motor. Check air supply, regulator, and hose.
The mandrel is bent and/or jammed in the prewinder threads. 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.
The mandrel is jammed in the adapter drive sleeve. 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.
Mandrel damages the insert in the prewinder, or tapped hole. Worn tip on mandrel, and/or worn threads on prewinder. 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.
Tapped holes out of specification. 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.
Mandrel does not retract after insert is installed, and air motor reverses. Mandrel continues to spin. 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.
Installed depth of the insert varies, or is out of specification. Using the wrong spacer on the mandrel. Check for correct spacer to correspond with the insert length. Change if required.
Countersink is out of specification or is inconsistent from hole to hole. Check countersink diameter and angle per MS33537, or KFS catalog. Make corrections as required.
Lack of shim washers. Add the shim washers that come with the front end assembly over the mandrel to decrease the installation depth as required.
Spacer is too thick. The spacer can be machined down to increase the installation depth.
Excessive or premature mandrel wear. (Also applies to pawls on Tangless tools.) Excessive air pressure. 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.
Worn prewinder threads. Replace Prewinder.
Misalignment. 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.
Tapped holes out of specification. 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.
Air motor runs slow and/or is making excessive noise. Low air pressure. No lubrication. Dirty air supply. 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.
Air motor is worn or damaged. 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.
Front end assembly components are binding or are damaged. Disassemble front end assembly. Lubricate all moving parts, including adapter keyway. Make sure all parts turn freely. Replace worn or broken components.
Tangless Insert slips over the pawl, and runs up the mandrel. Pawl is worn or broken. Replace worn pawl with new one.
Mandrel threads are worn. Replace mandrel assembly with new one.
Pawl does not move freely in mandrel slot. Make sure slot is free of debris, and pawl moves freely.
Missing pawl spring. Check for missing spring. Disassemble mandrel and replace spring.
Air motor continues to run after mandrel retracts into adapter Worn or stripped rear threads in the prewinder. Replace prewinder.
Mandrel not bottoming out on cushion in adapter sleeve. Add an additional plastic cushion to the bottom of the drive sleeve in the adapter.
Mandrel does not rotate and move forward with air motor running in the forward direction. 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.
Mandrels and/or pawls are breaking prematurely. Failure to use the Air Motor Clutch Drive. 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.
Excessive air pressure. Check pressure on filter-lubricator-regulator gage vs. maximum PSI imprinted on prewinder. Use the lowest air pressure that will install the insert.
Misalignment. 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.
Operator error. Refer to instructions included with the air motor and front end assembly. Contact the KATO Tech Group by phone, or at techgroup@katonet.com
Tangless mandrel will not thread into the rear prewinder threads upon assembly. Hook (tip) of pawl is preventing the mandrel from engaging the prewinder threads. Press on the pawl to retract the pawl tip and thread the mandrel into the prewinder.
Worn or broken mandrel, or prewinder threads. Replace worn or broken components as required.

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