NIPPON POP RIVETS AND FASTENERS PRL600A User manual

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ＰＲＬ６００Ａ
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”ＰＯＰ”ＲＩＶＥＴＥＲ
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ＩＮＳＴＲＵＣＴＩＯＮＭＡＮＵＡＬ
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ＮＩＰＰＯＮＰＯＰＲＩＶＥＴＳＡＮＤＦＡＳＴＥＮＥＲＳＬＴＤ．
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2000.9.13 

Ⅰ．Outline
ThePRL600Aisapneumatic-hydraulictoolwithhighairpressurespecifications,
whichissuitableforsettingPOPrivetsφ4.0mm-φ4.8mm.

1.Models
Selectthemodelaccordingtotherivetsizeandconditionsofuse.(Table1)

Table１ ※Standardparts
 Rivetsize
(φmm) Nosepiece Mandrel guide
ass’y Ejectorcomplete
PRL600A-4,5 PRL600A-160/5
PRL600A-4,5-150L PRL600A-160/515
PRL600A-4,5-200L

 4:3.2
 5:4.0

4:PRN414
5:PRN514 PRL600A-160/520

PRL600A-161/5
PRL600A-6､6S PRL600A-160/6S
PRL600A-6､6S-150L PRL600A-160/6S15
PRL600A-6､6S-200L
4.8

6:PRN610
6S:PRN6S0 PRL600A-160/6S20

PRL600A-161/6S
Model
*Therivetsizecanbechangedbyinterchangingthenosepiece,mandrelguide
assemblyandejectorcomplete.
2.Nosepiece
Useanappropriatenosepieceaccordingtothetypeandsizeofrivet.
(Table2)
Usingadifferentsizenosepiecemaycausefaultyrivetsettingortool
malfunctions.
Table2

Closedend
Rivettype

Rivet
diameter(φmm)

Openend 
Steelmandrel Aluminum mandrel Stainlesssteel mandrel
４．０ ＰＲＮ５１４ ＰＲＮ５２４ ＰＲＮ５３４ ＰＲＮ５１４
４．０(SD5HR) ＰＲＮ６１４ − − −
４．８ ＰＲＮ６１４ ＰＲＮ６２４ ＰＲＮ６３４ ＰＲＮ６１４
４．８(SD6HR) ＰＲＮ６Ｓ − − −
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3.Toolspecifications
ToolspecificationsareasshowninTable3.
Table3
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Model Weight
(kg) Length (mm) Height (mm) Stroke (mm)
*Airpressure
(Mpa)
PRL600A-4,5,6,6S ０．９９ ２９３
PRL600A-4,5,6,6S-150L １．０９ ３３９
PRL600A-4,5,6,6S-200L １．１９ ３９０

２５０  １８ 0.35〜0.8
(3.6〜8.2kgf/cm2)
*ThePRL600Ahashighairpressurespecifications.Itisnormallyusedat
between0.35Mpa
and0.8Mpa,butcanalsobeusedatlowerairpressuresdepending
onthetypeandsizeofrivet.
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１

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Table4–Minimumrequiredairpressure(MPa)
Openend Closedend
Rivettype

Rivetdiameter
(φmm)
AD-ABS TAP-BS
TAP-HR SD-BS TAP-SSBS SD-HR SSD-BS SSD-SSBS AD-AH AD AD-SSH SSD-SSH
３．２ 0.35 0.4 0.45 0.4 0.5 0.35 0.4 0.5
４．０ 0.4 0.55 0.5 0.55 0.65 − 0.55 0.65
４．８ 0.45 0.65 0.65 0.7 − 0.45 0.65 −
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Ⅱ．Methodofuse(Figure１)
1.Connecttheairhosetotheairhosetip
joint(Rc1/4).
2.Whenarivetmandrelisinsertedintothe
nosepiece,therivetwillbedrawninbythe
MCS.
3.Therivetissetbypullingthetrigger.
4.Spentmandreliscollectedinthecatcherby
theMCS.
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(Note)TheMCSsuctionpressureisadjusted
(strong-weak)withthevalveshutterscrew
adjustment.TheshuttershouldbeclosedwhentheMCSisnotusedorwhenthe
toolisleftunattendedforlongperiodswiththeairconnected.(Screwthe
valveshutteruntilitstops.)
Valveshutter
(PRL600-25) MCS
Catchercomplet
e
(PRL800-50)
Joint(Rc1/4)
Figure1
Trigger
(PRL600-72)
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Ⅲ．Cautionsforuse
1.Airpressure
Alwaysensurethatthetoolhassufficientairpressuretosetrivets.If
thenecessaryairpressurecannotbeensured,useaboostervalve.
(Reference:Theairpressurecanbeboostedfrom0.4MPato0.8Mpawiththe
SMCVBA2100-03GN).
2.Oil
SelectanappropriateoilfromTable5.Usingtypesofoilotherthanthose
listedinTable5maycausemalfunctions.


Table5
Companyname Productname Companyname Productname
EssoStandardOil Tel-Esso52.68 MitsubishiOil DiamondRulerRO68
NipponOil FBKRO68 MobilOil MobilDTE46.68
CosmoOil CosmoHydroRO68 KyodoOil KyosekiHydroW68
IdemitsuPetroleum DuffneyHydro46.68 ShellOil ShellTerraceOilC68
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2

3.MCSmandrelholdingcapacity
TheMCSmandrelholdingcapacityfluctuatesaccording Rivetdiameter
(φmm)Maximum capacity
４．０ １００
４．８ ７０
Table6
totheairpressureandsuctionstrength.Maximum
capacitiesareasshowninTable6.

Themandreldiscardtimingisbestwhenthemandrelsreachapproximatelyhalf
thevolumeofthecatcher.
Figure2 Catcher
(Note)Exceedingthemaximumcapacity
maydamagetheMCSorcausemandrelsto
becomestuckinsidethetool.

Ⅳ．Maintenanceandinspections

 Item Frequency Purpose
１ Sprayinglubricantintothe
jaws Every500rivets Maintainsproperjawoperationand extendstheservicelife.
２ Cleaningthetipparts Every3,000rivets Removesmetalpowderandextends
theservicelife.
３ Addingoil Every30,000rivets Strokerecovery;preventsfaulty
operation.
４ Replacingthejaws Every50,000rivets Replacedduetotheservicelife;
preventsfaultyoperation.
５ Replacingthenosepiece Every100,000rivets ↑↑
６ Replacing the jaw pusher
spring Every20,000rivets ↑↑
７ Replacingtheseals Every100,000rivets ↑↑
８ Replacingthejawcase Every100,000rivets ↑↑

1.Sprayinglubricantontothejaws(Figure3)
Lubricating and rust-proofing agents (CRC type) should be sprayed into the
nosepieceholeapproximatelyevery500rivetsinordertomaintainproperjaw
operation.Alwaysclosethevalveshutterwhensprayingthejaws.(Ifthejawsare
sprayingwiththeairconnected,thelubricatingoilwillbedrawnintotheMCS
andmissthejaws.)

Nosepiec
e
(PRN-□)
Sprayoil
Figure3
(reference)
Manufacturer Productneme
KureIndustriesInc. CRC5-56
ThreeBondInc. 1801B
MusashiHoltzInc. HoltzTopOilMH241
LesupiInc. Pikka
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2.Cleaningthetipparts
Cleanthetippartsregularly(twoorthreetimespermonth).Aftersetting2,000–3,000rivets,
metalpowderwilladheretothetippartscausingtoolactiontodeteriorateandthejawsto
slip.Continuingoperationundertheseconditionswillshortentheservicelifeofthejaws
andothertipparts.
(1)Loosenthenosehousingwithawrenchandremoveit.(Figure4)
(2)Releasetheconnectorlockbyhand,andremovethejawcasefromthepullinghead.
(3)ThepartswhichwillcomeoffareshowninFigure5.Cleanthesepartsandthenosehousing
withkeroseneorasimilaroil.Inaddition,blowairthroughthepullingheadandnose
housingtocleanthem.
MandrelguideAss’y

(
PRL60
0
-160
/
□
)

(4)Whenassemblingtheseparts,spraytheinsideofthejawcase(CRCtypeoil).Then,lock
thejawcaseonenotchbackfromthecompletelyclosedposition.




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







Nosehousing
(PRL600-03) Jawcase
(
PRL60
0
-15
)
Figure4
Connector lock
(PRL600-01) Pullinghead
(PRL600-21,22,112)
Figure5 Jawpusher

(
PRL60
0
-58
)
Jaw
(
PRG54
0
-46B
)

Jawcase
(
PRL60
0
-15
)
Jawpushersprin
g

(
PRL60
0
-20
)
3.Addingoil
Whentheoilbecomeslow,resultinginaninsufficientstroke,orwhentheoilisdrainedout
inordertoreplacetheseals,oilshouldbeaddedaccordingtothefollowingprocedures.There
aretwomethodsofaddingoil;thesimplemethodandthenormalmethod.
(1)Simplemethod(Figure6)
Thismethodisconvenientwhenaddingoilwithoutreplacingtheseals.
(1)First,disconnectthetoolfromtheairsupply,andremovethefillscrewandthe
nosepiecewiththeaccessorywrench.
(2)Addoilwhileusingthehexagonalwrenchtoscrewtheoilreplacementscrewintothe
nosehousing.
(3)Afterscrewingintheoilreplacementscrewuntilitstops,tightenthefillscrew.
Then,removetheoilreplacementscrew.
(4)Loosenthefillscrewandallowtheairandexcessoiltodrainout.Whenthepiston
returnstoitsoriginalposition,oilwillstopdrainingout.
(5)Repeatsteps(2)through(4)twoorthreetimestosufficientlydrainouttheair.Then,
tightenthefillscrew.








4

Fillscrew
(PRL600-23)
Oilreplacementscrew(option)
(PRL540-127)
Nosehousing Hexagonalwrench
(option)(PRL600-81A)
Figure6

(2)Normalmethod(Figures7and8)
Alwaysusethismethodwhenreplacingtheseals,etc.
(1)Removethenosehousing.
(2)Removethetubeassemblyfromthechamberwithascrewdriver.
(3)Removethefourcapscrewswithahexagonalwrench(4mm).Then,remove
thechamberfromthehandleandextracttheairpistonassemblyfromthe
handle.Wipeoffanydirtontheinsideofthechamberandaroundthe
outsideoftheairpiston,andcoattheseareaswithgrease.
(4)Pouroilintothehandleandworktheairpistonassemblytwoorthree
times.Repeatthisprocesstwoorthree
times.
Tubeassembl
y
(PRL600-95A) Chamber
(PRL600-55A)
Figure7
Capscrew
(PRL600-74)
Hexagonalwrench(4mm)
(5)Assemblethehandleandchamber.
(Figure9)
・First,placethechamberoverthehandle
whileslidingitalongtheairpiston.
Thisprocessiseasierifthechamber
istilted.Takecarenottoletthe
valveupperfall.
・Next,facethetoolupwardswhile
holding the handle and chamber
firmly together. Line up the cap
screwattachmentholesandtighten
thehandleandchambertogetherwith
thecapscrews.
・Finally,loosenthefillscrewand
drainouttheairandexcessoil.
Waituntiloilstopsdrainingoutandthen
tightenthefillscrew.
(6)Attachthetubeassemblyandnosehousing.

４．Replacingthejaws
Ifthejawsbeginstoslipshortlyafterbeing
cleaned,itisattheendofitslife.Removeand
replacetheoutlinedinsectionIV-2above.
５．Replacingthenosepiece
Whentheentrancetothenosepieceholebecomes
worn,rivetflangeswillstickupafterbeingset.
Thiscancausefaultyrivetsetting(areduction
instrength).Removethenosepiecefromthenosehousingwiththeaccessory
wrenchandreplaceit.

Airpiston
(PRL600-57)
Oil
Airpiston
assembly
(PRL600-93)
Ram
(
PRL60
0
-56
)
Handle
Ram
Chamber
Valveupper
(
PRL60
0
-68
)
Figure9
Handle
Figure8
６．Replacingthejawpusherspring
Ifthejawsslipevenwhenitisnotworn,thejawpusherspringhasbecome
fatigued.RemoveandreplacethejawpusherspringasoutlinedinsectionIV-2
above.
７．Replacingtheseals
Ifthestrokebecomesdeficientsoonafteraddingoil,thesealsareworn.
Sendthetooltothedealerormanufacturerforrepair.
８．Replacingthejawcase
Ifrivetsarenotsetevenwhenthetooloperates(reciprocatingmotion),the
jawcaseisbroken.Removeandreplacethejawcaseasoutlinedinsection
IV-2above. 5


PRL600A Dimensional drawing

6

Ⅴ．ＰＲＬ６００ＡＰａｒｔｌｉｓｔ
No. Productname ProductNo. Q'ty No. Productname ProductNo. Q'ty
1 NosepiecePRL600A-4 PRN414 1 23 MandrelguidePRL600A-4,5 PRL500-17/5 1
PRL600A-5 PRN514 1 PRL600A-4,5-150L PRL500-17/515 1
PRL600A-6 PRN614 1 PRL600A-4,5-200L PRL500-17/520 1
PRL600A-6S PRN6S 1 PRL600A-6,6S PRL600-138/6S 1
2 Jaws PRG540-46B 1set(2) PRL600A-6,6S-150L PRL600-138/6S15 1
3 Connectorlock PRL600-01 1 PRL600A-6,6S-200L PRL600-138/6S20 1
4 Lockpin PRM530-53 1 24 Lockring PRL600-19 1
5 Connectorlockspring PRL600-02 1 25 Jawpusherspring#5206 PRL600-20 1
6 Nosehousing PRL600-03 1 26 PullingheadPRL600A PRL600-21 1
7 Hydraulicpiston PRL600-04 1 PRL600A-150L PRL600-22
8 HousingadapterPRL600A PRL600-05 1 PRL600A-200L PRL600-112 1
PRL600A-150L PRL600-06 1 27 Fillscrew PRL600-23 1
PRL600A-200L PRL600-111 1 28 O-ringP5(U565) PRL600-24 2
9 ScraperSER10A PRM530-32 1 29 Valveshutter PRL600-25 1
10 Rodsealcase PRL600-07 1 30 O-ringS4(1A) PRL600-26 1
11 O-ringP20(U565) PRL600-08 2 32 JointPCC4M6M PRL600-28A 1
12 BuckupringT2P10A PRL600-09 1 33 Airtubeφ4×171L PRL600-29A 1
13 PentasealPS10A PRM530-30 1 34 Locknut PRL600-30 1
14 O-ringP6(1A) PRL600-10 1 100 Catchercomplete PRL800-50 1set
15 BuckupringT2P20 PRL600-11 1 91 Shutterassembly PRL800-49 1set
16 O-ringP20(1A) PRL600-12 1 40 Shutter PRL800-36 1
96 Handleupperassembly PRL600-82A 1set 41 Shutterwasher PRL500-39 1
17 Handleupper PRL600-13A 1 42 Pincase PRL500-40 1
31 LockscrewM3×4L PRL600-27 1 89 Pincasecap PRL600-102 1
18 Returnspring PRM530-18 1 43 Shutterpin PRL500-41 1
19 Endcap PRL600-14 1 98 SetringE型4 PRL600-103 1
20 Jawcase PRL600-15 1 44 Grip PRL600-39A 1
21 Jawpusher PRL600-58 1 45 Shutterspring#5113 PRL600-40A 1
90 MandrelguidePRL600A-4,5 PRL600A-160/5 1set 36 Catcherbody PRL800-34 1
assemblyPRL600A-4,5-150L PRL600A-160/515 1set 37 Adapter PRL800-35 1
PRL600A-4,5-200L PRL600A-160/520 1set 35 O-ring1030 PRL800-38 1
PRL600A-6,6S PRL600A-160/6S 1set 38 Shutterspacer PRL500-42 2
PRL600A-6,6S-150L PRL600A-160/6S15 1set 39 CapscrewM4×10L PSL600CJ-30 2
PRL600A-6,6S-200L PRL600A-160/6S20 1set
22 MandrelguidePRL600A-4,5 PRL600A-59/5 1
adapterPRL600A-6,6S PRL600A-59/6S 1
7

No. Productname ProductNo. Q'ty No. Productname ProductNo. Q'ty
92 EjectercompletePRL600A-4,5 PRL600A-161/5 1set 94 Valveassembly PRL600-94 1set
PRL600A-6,6S PRL600A-161/6S 1set 72 Valvelower PRL600-65 1
46 EjecternozzlePRL600A-4,5 PRL600-106 1 73 Valverod PRL600-66 1
PRL600A-6,6S PRL600-41 1 74 Bumper PRL600-67 1
47 Ejecterlock PRL600-42 1 75 Valveupper PRL600-68 1
48 EjecterbodyPRL600A-4,5 PRL600A-162/5 1 76 Springpinφ3×10L PRM530-43 2
PRL600A-6,6S PRL600A-162/6S 1 77 Valvepusher PRL600-69 1
49 EjecterpipePRL600A-4,5 PRL600-137/5 1 78 Handlefront PRL600-70 1
PRL600A-6,6S PRL600-137/6S 1 79 Triggerwire PRL600-71 1
50 Sleeveupper PRL600-45 1 80 Trigger PRL600-72 1
51 O-ringP10A(U565) PRL600-46 1 81 Springpinφ3×18L PRL600-73 1
52 Nutupper PRL600-47 1 82 CapscrewM5×14L PRL600-74 4
53 Handlerear PRL600-48 1 95 Tubeassembly PRL600-95A 1set
54 Sleevelower PRL600-49A 1 83 JointPL4M5M PRL600-75A 1
55 Nutlower PRL600-50 1 84 Tube PRL600-76A 1
56 PentasealPS12.5 PRL600-51 1 85 NippleLN-M5-M5 PRL600-77 1
57 BuckupringT2P12.5(PT) PRL600-52 1 86 JointLH-FM5-M5 PRL600-78 1
58 Handlelower PRL600-53A 1 88 PanheadscrewM3×16L PRL600-80 4
59 SetringISTW21 PRL600-90 1 Accessories
61 Chamber PRL600-55A 1 SprayCRC5-56 PRL600-98 1
67 PanheadscrewM5X6 PRL500-32 1 BrushD-32 PRL600-99 1
93 Airpistonassembly PRL600-93 1set Option
62 Ram PRL600-56 1 Chamberprotecter PRL600-156 1
63 Airpiston PRL600-57 1 Handleprotecter PSL600CJ-101 1
64 Airpistonseal PRT5200-28 1
66 Joint PRL600-89 1
68 Cap PRL600-62 1
69 O-ringS8(1A) PRL600-63 1
70 Valvespring#5082 PRL600-97 1
71 O-ringP4(U565) PRL600-64 1
8





Ⅵ．Cross-sectional diagram
9