2 MCS5800-HEX MANUAL ADDENDUM
1. POP Bolt™ Tool
1.1 Work Capacity
1.3 POP Bolts™ per battery charge
Style Description
Hex Washer Head Bolt
PBS-HWH-8-M6 (Steel)
PBSS-HWH-A2-M6 (Stainless Steel)
Slotted Truss Head Bolt
PBS-THS-8-M6 (Steel)
PBSS-THS-A2-M6 (Stainless Steel)
Twinfix PBSS-TFX-A2-M6 (Stainless Steel)
Collar
PCS-6S (Steel)
PCSS-6S (Stainless Steel)
PCA-6S (Aluminium)
1.2 Equipment/Accessories
Nosepiece: PSL600CJ-70A
Jaws A: PSL600CJ-59/12L (Standard)
Jaws B: PSL600CJ-59/14L (Recommended for nominal to max grip)
Bolt Material Rivets / Charge
M6 Steel 500
M6 Stainless Steel 400
260 mm
192 mm
62 mm
68 mm
92 mm
300 mm
ø66 mm
ø23.5 mm
Note
When using the
MCS5800-HEX tool,
all references to ‘rivets’ in
the MCS5800 Operating
Manual, should read
‘POP Bolts™’.
3MCS5800-HEX MANUAL ADDENDUM
2. Maintenance and Inspections
No. Item Purpose
2.1 Spraying lubricant into the
Jaws
Maintains proper Jaw operation and extends
the service life
2.2 Cleaning Jaws/Jaw Case To remove metal particles and prevent slippage or sticking of Jaws
To prevent early wear damage on Jaws and Jaw Case
2.3 Exchange of Hydraulic oil To restore stroke
2.4 Replacing the Nosepiece Because of wear or damage
2.5 Replacing the Jaw opener
assembly Because of damage
2.6 Replacing Jaws Because of wear or damage
2.7 Replacing Jaw pusher spring Because of weaken and worn damage
2.8 Replacing the Jaw case Because of damage
2.1 Spraying lubricant into the Jaws
Lubricating and rust-proofing agents (CRC type) should be sprayed into the Nosepiece hole
approximately every 2,000 pcs in order to maintain proper Jaws operation.
Manufacturer Product Name
Kure Industries Inc. CRC5-56
Three Bond Inc. 1801B
Musashi Holtz Inc. Holtz Top Oil MH241
Lesupi Inc. Pikka
Lubricant
(Reference)
Table 2
4 MCS5800-HEX MANUAL ADDENDUM
2. Maintenance and Inspections
2.2 Cleaning Jaws/Jaw Case (Fig. 2-2 and 2-3)
Clean the tip parts regularly. After fastening about 10,000 pcs., metal powder will adhere
to the tip parts and cause deterioration of tool action and slipping jaws.
(1) Loosen and remove the nose housing with a wrench.
(2) Removing the chuck spring will allow the chuck to be removed from the nose housing.
(The chuck spring can be easily removed using a small slotted screwdriver.)
(3) Remove the jaw case from the pulling head by attached 12mm spanners. The jaws will
come off at this time.
(4) Clean the parts by kerosene. Clean enough especially the tip of Nose housing (on the
side of Nosepiece).
Nose housing
JawNose housingNosepiece Jaw case Jaw opener
Chuck spring
Chuck
Inside of Chuck
Inside of Nose
Housing
Teeth of Jaw
Inside of Jaw case
Around Jaw opener
Fig. 2-2
Fig. 2-3
(5) When reassembling these parts, spray lubricant inside of the jaw case and on the jaws.
5MCS5800-HEX MANUAL ADDENDUM
2.3 Replacing the Nosepiece
Check the fastening condition of fastened sleeves with the accessory check gauge
(PSL600CJ-102A) before starting fastening work. (Fig. 2-4)
Continuing work with poor fastening conditions will cause insufficient fastening and
decreasing clinching force.
2.4 Replacing Jaw opener assembly
When Jaw opener assembly is damaged, replace with a new one by the procedure in 2.2.
2.5 Replacing Jaws
When Jaw slips soon even after cleaning, replace with new ones by the procedure in 2.2.
2.6 Replacing Jaw pusher spring
When Jaw pusher spring is damaged, or weakened, replace with a new one by the procedure
in 2.2.
2.7 Replacing the Jaw case
When the tool operation cannot fasten, it is caused by broken jaw case. Replace with a new
one by the procedure in 2.2.
To replace the nosepiece, remove the chuck as outlined in section 2.2.
Apply localised heat to the nosepiece and the nose housing to approximately 250 °C.
Disassemble while hot. (Fig. 2-5 shows the heated area.)
Then remove the nosepiece form the nose housing with the hexagonal wrench (5/16) and replace it.
Remove grease of the thread of new nosepiece and the screw hole of nose housing.
Apply Loctite 271 on the thread of new nosepiece.
Tighten the nosepiece to the nose housing by the hexagonal wrench (5/16).
Fig. 2-4
Fig. 2-5
Check
A grade difference indicates
that fastening is okay.
Even surfaces or gaps indicate that the
nosepiece should be replaced.
Even Gap
Nosepiece
Heated area
Nose housing
Note
The tightening force of nosepiece
has the specified torque values.
Torque values: 17±2.5Nm
6 MCS5800-HEX MANUAL ADDENDUM
3. Troubleshooting
Symptom Causes Troubleshooting
One trigger
operation does
not allow
breaking bolt
1. Slippage of jaws
Because metal particles are clogged in jaw’s
teeth or teeth are worn, the jaws cannot
catch mandrels, causing slippage.
Clean the jaws. If fault is not corrected
after cleaning, replace the jaws with
new ones (see pages 4, 5)
2. Stroke is too short.
Discharged Battery Recharge battery.
Lack of sleeve
swaging Nosepiece is worn or damaged. Replace nosepiece with a new one.
(see page 5)
Bolt cannot be
inserted into
Nosepiece, or
bolt cannot be
ejected after
setting
1. Jaws are broken. Replace jaws with new ones. (see page 5)
2. Jaw opener assembly is damaged. Replace jaw opener assembly with a
new one. (see page 5)
3. Jaw pusher spring is broken. Replace jaw pusher spring with a new one.
(see page 5)
4. Collector is full of bolt scraps. Discard bolt scraps in the collector.
Bolt doesn’t
break Jaw case is broken. Replace jaw case with a new one.
(see page 5)
(If you cannot fix the tool after checking the content of this section, send it to your
supplier or one of our offices for repair.)
7MCS5800-HEX MANUAL ADDENDUM
4. Parts List
Item Part No.
1 MCS5800-1
2 MCS5800-2
3 MCS5800-3
4 MCS5800-4
5 MCS5800-5
6 MCS5800-6
7 MCS5800-7
8 MCS5800-8
9 DPN901-015
10 PSL600CJ-78A/ST
11A PSL600CJ-59/12L
11B PSL600CJ-59/14L
12 PSL600CJ-90
13 PSL610NK-01
14 PSL600CJ-70A
Item Part No.
15 PSL600CJ-74
16 PSL600CJ-72
20 MCS5800-20
22a MCS5800-22a
25 MCS5800-25
26 MCS5800-26
27 MCS5800-27
28 MCS5800-28
29 MCS5800-29
30 MCS5800-30
31 MCS5800-31
32 MCS5800-32
33 MCS5800-33
35 MCS5800-35
36 MCS5800-36
Item Part No.
37 MCS5800-37
39 MCS5800-39
40 MCS5800-40
45 MCS5800-45 K
45 MCS5800-45 E
45 MCS5800-45 S
45 MCS5800-45 J
47 MCS5800-47
48 PSL600-5800 INT
49 PSL600-5800 EXT
Options
50 PSL600CJ-102A
2530
1
39
35
36
37
26 32
9 10 11A
11B
12 13 14 15 16
7 4849
54
32
31
40
45
29
28
27
20
22a
47
8
2 3
6
33
50
© Emhart Teknologies 2009
POP® is a registered trademark of Emhart Teknologies.
POP Bolt™ is a trademark of Emhart Teknologies.
Quality systems approvals from the world’s household names in manufacturing serve to reinforce accreditation to QS9000 / ISO9001 / TS16949.
As a result of our continuous design improvement, Emhart products are subject to modification. The latest technical data and drawings are
available for any specific products on request.
www.emhart.com
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Tucker Fasteners
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United Kingdom
Tel: +44 121 356 4811
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AMERICAS ASIA
6405/GB/0709
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