Huck 255, 256 Instruction Manual

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Page 1

INSTRUCTION MANUAL

255

PNEUDRAULIC INSTALLATION

TOOL

HK1014 Rev. 03/18/03

HUCK FASTENERS HUCK FASTENERS HUCK FASTENERS HUCK FASTENERS HUCK FASTENERS HUCK FASTENERS HUCK FASTENERS HUCK FASTENERS

HUCK

255

U.S. PAT. 4597263

Page 2

MODEL 255 TOOL HUCK FASTENERS

EU Declaration of Conformity

Manufacturer:

Huck International, Inc., Installation Systems Division, 1 Corporate Drive, Kingston, NY, 12401, USA

Description of Machinery:

Model number 255 fastener installation tool

Relevant provisions complied with:

Council Directive related to Machinery, (89/392/EEC), (91/368/EEC), (93/44/EEC), (93/68/EEC)

European Representative:

Rob Pattenden, Huck International, Ltd. Unit C Stafford Park 7, Telford Shropshire TF3 3BQ, England, United Kingdom

Authorized Signature/date:

I, the undersigned, do hereby declare that the equipment specified above conforms to the above Directive(s) and Standard(s).

Signature: ___________________________________

Full Name: Henk Rosier

Position: Engineering Manager,

Installation Systems Division

Place: Kingston, New York, USA

Date: August, 1998

Huck Model 255 Sound Level

The sound level of the 255 tool cycling without fastener is

Sound Exposure Level (SEL) =84.4 dB (A) Peak Value = 91.1 dB (C)

The noise of the fastener being installed in structure is considered process noise, not tool noise. Sound measurements of simulated process noise are available upon written request from Huck International in Kingston, NY, USA.

Huck Model 255 V

ibration Level

For an eight hour work day, installing 3000 typical Huck fasteners will result in an equivalent weighted RMS vibration level (Aeq) of 8.1m/s2.

To calculate the equivalent vibration level for other quantities of fasteners in an eight hour period, use the formula:

Equivalent Vibration Level, Aeq (m/s2) = (n/480) x 1.3

where n = number of fasteners in eight hours, and

1.3(m/s2) = Aeq for 60 seconds.

Test data to support the above information is on file at Huck International, Inc., Kingston, NY, USA. Vibration measurements are frequency weighted in accordance with ISO 8041 (1990).

Page 3

MODEL 255 TOOL HUCK FASTENERS

EU DECLARATION OF CONFORMITY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CONTENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

TOOL S

PECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SAFETY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

PRINCIPLE OF OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

PREPARATION FOR USE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

ERVICING THE TOOL

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11

Fill and Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12

Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

ACCESSORIES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

SERVICE NOTES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

CONTENTS

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MODEL 255 TOOL HUCK FASTENERS

TOOL SPECIFICATIONS

• Stroke: .625

• Weight: 8.8 lbs

• Air Pressure: 90-100 psi

• Capacity: 7750 lbs @ 90 psi

• Speed/Cycles: 30 per minute

• Noise Level: 85 dBA @ 90 psi

INCHES

7.091

180.11

.959

24.36

1.920

48.77

14.86

377.59

4°

HUCK

255

U.S. PAT. 4597263

4.610

118.00

6.020

153.00

3.957

100.51

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MODEL 255 TOOL HUCK FASTENERS

SAFETY

This instruction manual must be read with particular attention to the following safety guide lines, by any person servicing or operating this tool.

Safety Glossary

WARNINGS - Must be understood to avoid severe personal injury.

CAUTIONS - show conditions that

will damage equipment and or

structure.

Notes - are reminders of required procedures.

Bold, Italic type and underlining -

emphasizes a specific instruction.

2 Huck equipment must be maintained in a

safe working condition at all times and inspected on a regular basis for damage or wear. Any repair should be done by a qualified repairman trained on Huck procedures.

3 Repairman and Operator must read and

understand any Warning and Caution stickers/labels supplied with equipment before connecting equipment to any primary power supply. As applicable, each of the sections in this manual have specific safety and other information.

4 When repairing or operating Huck

installation equipment, always wear approved eye protection. Where applicable, refer to ANSI Z87.1 - 1989

5 Disconnect primary power source

before doing maintenance on Huck equipment.

6 If any equipment shows signs of

damage, wear, or leakage, do not connect it to the primary power supply.

7 Make sure proper power source is used

at all times.

8 Never remove any safety guards or

pintail deflector.

9 Never install a fastener in free air.

Personal injury from fastener ejecting may occur.

10 Do not abuse tool by dropping or using

it as a hammer. Reasonable care of installation tools by operators is an important factor in maintaining tool efficiency, eliminating downtime, and in preventing an accident which may cause severe personal injury.

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MODEL 255 TOOL HUCK FASTENERS

When the trigger is depressed, the throttle valve moves to down position, and pressurized air is directed to the bottom of the air piston, causing the piston to move upward. The air above the piston is exhausted and directed through the center of the throttle valve and out the bottom of the tool. The air piston has a rod and a hydraulic piston attached. When the air piston rod moves upward, a column of pressurized fluid is forced into head, which moves the pull piston back. The attached nose assembly moves with the pull piston to start fastener installation.

When fastener installation is completed, the trigger is released. Air pressure, with the assistance of a spring, causes the throttle valve to return to its up position. Pressurized air is re-directed to the top of the air piston, causing the piston to move downward. The air from below the piston is exhausted through bottom of tool. The rod and hydraulic piston move downward, hydraulic pressure is reversed and the pull piston is returned forward. Return pressure relief valve protects tool against pressure spikes. The reservoir replenishes hydraulic system as needed.

PRINCIPLE OF

OPERATION

PULL RETURN

PULL PISTON

RELIEF VALVE

HYDRAULIC PISTON

THROTTLE VALVE

CHECK VALVE

RESERVOIR

EXHAUST

AIR PISTON

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MODEL 255 TOOL HUCK FASTENERS

The Model 255 Installation Tool is shipped with a plastic plug in the air inlet connector. The connector has 1/4-18 female pipe threads to accept the air hose fitting. Quick disconnect fittings and 1/4” inside diameter air hose are recommended. An air supply of 90-100 psi capable of 11.5 CFM must be available. Air supply should be equipped with a filter-regulator-lubricator unit.

1. Remove plastic shipping plug from Air Inlet Connector and put in a few drops of Automatic Transmission Fluid, DEXRON III, or equivalent.

2. Screw quick disconnect fitting into Air Inlet Connector.

CAUTION: Do not use TEFLON tape on threads - - use

TEFLON in stick form only. (Huck P/N 503273)

3. Set air pressure on regulator to 90-100 psi.

4. Attach optional Air Hose (38), supplied with tool, to air inlet connector.

5. Connect air hose to tool.

6. Cycle tool a few times by depressing and releasing trigger.

7. Disconnect air hose from tool.

8. Remove Retaining Nut and Stop.

9. Select proper Nose Assembly from SELECTION CHART for fastener to be installed.

10. Screw Collet Assembly (including lock collar and shim if applicable) onto Spindle holding Pull Piston (11) with 3/8 hex key. (Wrench Tight)

11. Slide Anvil over Collet Assembly and into counterbore.

12. Slide Stop and Retaining Nut over Anvil and screw Nut onto Head.

13. Connect air hose to tool and install fastener(s) in test plate of proper thickness with proper size holes. Inspect fastener(s).

NOTES:

1 Air quick disconnect fittings and air hoses are not

available from Huck International, Inc.

2 VIBRA-TITE should be used on collet threads for nose

assemblies without lock collars. All other noses should be staked (please refer to nose assembly data sheets).

PREPARATION FOR USE

GENERAL

1. The efficiency and life of any tool depends upon proper maintenance. Regular inspection and correction of minor problems will keep tool operating efficiently and prevent downtime. The tool should be serviced by personnel who are thoroughly familiar with how it operates.

2. A clean, well-lighted area should be available for servicing the tool. Special care must be taken to prevent contamination of pneumatic and hydraulic systems.

3. Proper hand tools, both standard and special, must be available.

4. All parts must be handled carefully and examined for damage or wear. Always replace Seals, when tool is disassembled for any reason. Components should be disassembled and assembled in a straight line without bending, cocking, or undue force. Disassembly and assembly procedures outlined in this manual should be followed.

5. Service Parts Kit 255KIT includes consumable parts and should be available at all times. Other components, as experiece dictates, should also be available.

DAILY

1. If a Filter-Regulator-Lubricator unit is not being used, uncouple air disconnects and put a few drops of Automatic Transmission Fluid or light oil into the air inlet of the tool. If the tool is in continuous use, put a few drops of oil in every two to three hours.

2. Bleed the air line to clear it of accumulated dirt or water before connecting air hose to the tool.

3. Check all hoses and couplings for damage or air leaks, tighten or replace if necessary.

4. Check the tool for damage or air/hydraulic leaks, tighten or replace if necessary.

5. Check the nose assembly for tightness or damage, tighten or replace if necessary.

6. Check oil level in tool reservoir, replenish if necessary.

EEKLY

1. Disassemble and clean nose assemblies and reassemble per applicable NOSE ASSEMBLY DATA SHEET.

2. Check the tool and all connecting parts for damage or oil/air leaks, tighten or replace if necessary.

ERVICING THE TOOL

WARNING: Inspect tool for damage or wear before each use. Do not operate if damaged or worn, as severe personal injury may occur.

Page 8

MODEL 255 TOOL HUCK FASTENERS

MODEL 255 DISASSEMBLY INSTRUCTIONS

For component identification and Parts list, refer to Figure 9.

Disassembly

(Refer to Figures 1 thru 4 and 9)

NOTE:

The following procedure is for complete disassembly of tool. Disassemble only components necessary to replace damaged O-rings, Quad rings, Back-up rings, and worn or damaged components. Always use soft jaw vice to avoid damage to tool.

1. Disconnect air hose from tool.

2. Remove nose assembly. Follow instructions on Nose Assembly Data sheet.

3. Insert Fill Tool P/N 112465 through reservoir housing and screw into Reservoir Plunger (79) locking it in the out position. (Fig. 1)

4. Unscrew Cap Screws (69) with 5/32 hex key. Carefully lift Head (89) straight up from Handle (1), remove Pull Gland (90) and Return Gland (22) from separated assemblies. Remove seals from glands. (Fig. 1)

5. Unscrew Plug (83) of return Pressure Relief Valve from front of head. Remove Spring (84), Valve Guide (86), Sleeve (85) and Steel Ball (87). A small magnet is helpful. (Fig. 1)

6. Unscrew Bleed Plug (64). Hold over waste oil container and release fill tool slowly. (Fig. 1)

7. Unscrew Reservoir Housing (81) from head. Remove two Springs (82). Slide Reservoir Plunger (79) from head. Remove spacer and Quad Ring (80). A pick may be used to remove the quad ring. (Fig. 1)

8. Unscrew Plug (71) of reservoir check Valve from side of head. Remove Spring (75), check Valve Guide (76) and Stainless Steel Ball (77). (Fig. 1)

9. If check Valve Seat (78) is damaged contact your Huck representative. If Seat (88) is damaged it can be removed by using the following procedure.

NOTE: If seat is taken out it can not be reused, it must

be replaced. (Fig. 9)

10. (Seat 88 removal) Note: all parts in the reservoir

check valve must be removed before Plug (70) can be removed. Unscrew Plug (74), insert a #10 screw in the

thread of Plug (70), and pull to remove. Using a small drift and hammer, from the rear side of the head, drive Seat (88) out towards the front of the head. (Fig. 9)

11. Pintail Deflector (21) can be pulled off barbed end at rear of Pull Piston (11).

12. Unscrew End Cap (20) from Head (89) with 1 9/16 open end wrench. (Fig. 9)

13. Place Spacer (123112-1) on Pull Piston (11), and screw Assembly/disassembly Bullet (123111-1) onto piston. Tap or press piston assembly out of head.

NOTE: This will push out front and rear gland assemblies

and wiper and wiper housing. (Fig. 2)

WARNING: Be sure air hose is disconnected from tool before cleaning, or performing maintenance. Severe personal injury may occur if air hose is not disconnected.

FIG. 1

FILL TOOL 112465

SPACER

LOCK-OUT POSITION

82 (2)

69 (4)

HUCK

U.S. PAT. 4597263

255

Page 9

MODEL 255 TOOL HUCK FASTENERS

14. Remove Screw (67) from Throttle Arm (66). Remove throttle arm. Pull Throttle Valve (36) out of cylinder. Remove Spring (40). (Fig. 9)

15. With a small punch and hammer, drive Roll Pin (5) that retains the trigger from Handle (1). Remove trigger pin (4). Remove ball end of Cable (2) from throttle arm (66), and pull cable out of handle. (Fig. 9)

16. Remove Bleed Plug (64) from handle. (Fig. 1)

17. Hold tool inverted in vice. Unscrew three Button Head Screws (45) with 1/8 hex key. (Fig. 3)

18. Remove Muffler End Cap (42), Bottom Exhaust Gasket (46), Muffler (43) and O-ring (44). (Fig. 3)

19. Remove Retaining Ring (47) from Cylinder Assembly (53). (Fig. 3) NOTE: Tap cylinder head down into cylinder for easier removal of retaining ring.

20. Screw Button Head Screws (45) into Cylinder Head (49). Carefully pry under screws to remove cylinder head.

21. Push air piston all the way down in cylinder, and lay tool on its side. Hold Self-locking Nut (41) with a 9/16 socket and extension and with 7/64 hex key, remove piston Screw (32). (Fig. 4 & 9)

22. Turn cylinder and handle upside down and secure in a vise.

23. Grip Self-locking Nut (41) under Air Piston (51) with pliers and pull piston and rod assembly from handle and cylinder assembly. (Fig. 3 & 4)

CAUTION: Care must be taken not to scratch piston rod or cylinder during removal.

24. With a 1 3/8 socket and extension, remove Gland Assembly (54). Handle and cylinder will now separate. (Fig. 3)

25. Push Hydraulic Piston (31) out of handle. Push out from top to bottom.

CAUTION: A plastic or wooden drift must be used to

avoid damaging the handle bore.

26. To remove Polyseal (61) from Gland Assembly (54), remove Retaining Ring (59) and Spacer (60). (Fig. 9)

FIG. 3

FIG. 2

47 49 48

123111-1 ASSEMBLY BULLET

123112-1 SPACER

255

HUCK

U.S. PAT. 4597263

10 (NOTE

POLYSEAL DIRECTION)

Page 10

MODEL 255 TOOL HUCK FASTENERS

Assembly (Refer to Figures 1 thru 5 and 9.)

Clean components with mineral spirits, or similar solvent. Inspect for wear/damage and replace as necessary. Replace all seals of disassembled components. Use Orings, Quad rings and Back-up rings in Service Parts Kit, P/N 255KIT Smear LUBRIPLATE 130AA or PARKER-OLUBE on O-rings, Quad rings, Back-up rings and mating parts to ease assembly. Assemble tool taking care not to damage O-rings, Quad rings, or Back-up rings.

1. Holding handle inverted in a vice, Place Cylinder (53) on handle with Timing Pin positioned in matching hole. Assemble Gland Assembly (54). (Fig. 9) Screw complete gland assembly into handle. Torque to 100 120 ft. lbs. using 1 3/8 socket wrench.

2. Push Air Piston/Rod assembly with Quad Ring (50) in place into Air Cylinder until it bottoms at top of Cylinder. (Fig. 3)

3. Turn tool upright. Install Hydraulic Piston Assembly (31) (with O-ring (33) and Back-up Rings (27) in place) in handle. Press in from top of handle taking care not to damage seals. (Fig. 4)

4. Push Screw (32) with O-ring (35) in place through Hydraulic Piston (34) and screw into top of piston rod. Hold Self-locking Nut (41) with 9/16 socket and extension and torque Screw (32) using 7/64 hex key to 55 - 60 in. lbs.

5. Hold handle in vise with bottom facing up. Push Cylinder Head (49) with O-ring (48) in place squarely into cylinder. Install Retaining Ring (47). (Figs. 3 & 9)

6. Position O-ring (44) and Muffler (43) on center of Cylinder Head (49). Place Gasket (46) on Cylinder Assembly (53). NOTE: Lip must face Muffler End Cap (42). Place Muffler End Cap (42) on top of Gasket (46), and secure with 3 Button Head Screws (45) using 1/8 hex key. (Fig. 3)

7. Turn tool upright. Drop Spring (40) into Throttle valve hole in cylinder. Push Throttle Valve (36) with O-rings (37 & 39) in place into cylinder. (Fig. 9)

8. Assemble Trigger (3) Cable (2) and Trigger Pin (4), and slide cable into Handle (1). Align hole in trigger with hole in handle and install Roll Pin (5) with a hammer and punch. (Fig. 9)

9. Slide Throttle Arm (66) onto ball end of Throttle Cable. Swing arm until other end fits over throttle valve. Push Screw (67) through Throttle Arm (66). Tighten with 5/32 hex key.

10. If Air Hose Assembly (38) was removed, reinstall in Cylinder Assembly (53).

11. (If seat (88) is being replaced) Push Plug (70) (with O-ring 72 & Back-up Ring 25 in place) into head. Install Screw (74). (Fig. 9)

12. Install O-ring (72) and Back-up rings (25) onto seat. Drive seat and seal assembly in using soft drift taking care not to damage ball seat surface. (Fig. 1 & 9)

13. Assemble Pull Piston (11) with new Seals (12 & 13). Lubricate with LUBRIPLATE or PARKER SUPER-OLUBE. (Fig. 9)

14. Thread Assembly Bullet (123111-1) onto Pull Piston (11) and push entire assembly into head. (Fig. 2) NOTE: Spacer (123112-1) is not needed for this procedure.

15. Push Front Gland (97) with O-ring (14), Back-up Ring (15), Polyseal (10), Wiper Housing (91) and Wiper Seal (9) in place onto Pull Piston (11). (Fig. 2)

FIG. 4

MODEL

255 ASSEMBLY

INSTRUCTIONS

31 Piston Assembly

Page 11

MODEL 255 TOOL HUCK FASTENERS

16. Install O-rings (16 & 18) and Back-up Rings (17 & 19) on Rear Gland (93). Push complete assembly into head, screw in End Cap (20) and tighten. (Fig. 9)

17. Install O-ring (72) & Back-up Ring (25) on Plug (83). Install Ball (87), Valve Guide (86), Sleeve (85), Spring (84) and Plug (83) into head. (Fig. 1 & 9).

18. Install O-ring (65) on Plug (71). Install Ball (77), Guide (76), Spring (75) and Plug (71) into head.

19. Push Pintail Deflector (21) onto barbed end of Pull Piston (11). (Fig. 9)

20. Place O-ring (65) on Bleed Plug (64) and screw assembly into Handle (1). (Fig. 9)

21. Install O-rings (24 & 30) & Back-up Rings (25 & 29) on Pull Gland (28). Install O-rings (24 & 26) & Back-up Rings (25 & 27) on Return Gland (23). Push Gland Assemblies (22 & 90) into handle. Push Head Assembly (89) down on glands. Place tool in a vise, head down, and install 4 Cap Screws (69) and torque to 170 inch pounds. (Fig. 5)

22. Tool is now completely assembled and ready for Fill & Bleed.

FILL AND BLEED MODEL 255

Equipment Required:

- Shop airline with 90 - 100 psi max.

- Air regulator

- Fill bottle, 120337, (supplied with tool).

- Large flat blade screwdriver

- Optional Stall Nut 120824

- Nose assembly

- Fasteners (Optional)

Preparation:

1. Install air regulator in airline and set pressure to 20-40 psi.

2. Fill bleed bottle almost full of DEXRON III - ATF or equivalent. (Fig.6)

Refill tool only when red line on plunger drops below the red line on the reservoir housing or when tool is rebuilt.

USE: AUTOMATIC TRANSMISSION FLUID DEXRON III, OR EQUIVALENT.

Step 1

Screw Fill Tool P/N 112465 into Reservoir Plunger, pull Plunger into Housing and lock Fill Tool in full forward position by tilting handle (long side touching tool) and locking in place. (Fig.7)

Step 2

Remove Plugs (83) and (71) and all guides, springs and balls from ports in head. Reinstall Plug (83) in head in Relief Valve port (front of tool). (Fig 7 & 8)

Step 3

Screw retaining nut onto head assembly. Screw stall nut (optional see note:) onto piston and tighten to ensure full thread engagement. Back off retaining nut until it engages stall nut. Check piston location. Piston must be all the way forward and locked with stall nut and retaining nut.

NOTE: If Stall Nut is not used, piston must be pushed to the full forward position before installing valves.

Step 4

Attach the tool air source momentarily to seat air piston at bottom of cylinder. Disconnect tool. With fill port facing up, (check valve on side) lay tool on its side.

Step 5

Install fill bottle in head fill port (check valve hole). (Fig. 7 & 8)

FIG. 5

WARNING: Avoid contact with hydraulic fluid. Hydraulic fluid must be disposed of in accordance with Federal, State and Local Regulations. Please see MSDS for Hydraulic fluid shipped with tool.

FIG. 6

FILL POINT

120337 FILL BOTTLE ASSEMBLY

69 (4)

Page 12

MODEL 255 TOOL HUCK FASTENERS

Step 6

Connect tool to shop air regulated to 20 to 40 psi. Cycle tool 20 - 30 times. Watch for air bubbles escaping from the tool into bottle. (You may rock the tool to free trapped air in the tool.) Do not allow the air to re-enter the tool.

Step 7

When air bubbles no longer appear in bottle, remove fill bottle while tool is lying on its side.

Step 8

Install the check valve Ball (77), Guide (76) and Spring (75). Replace the Plug (71). (Fig. 7)

Note: When cycling tool, always hold bottle up as shown in Figure 8 to prevent drawing in air from empty part of bottle.

Step 9

Turn tool so front of head faces you and remove the relief valve Plug (83) and install relief valve Ball (87), Guide (86), Sleeve (85) and Spring (84). Replace the Plug (83).

Step 10

Unlock Fill Tool and check Reservoir red line. At this point cycle tool with Stall Nut attached (Optional. See note.) and retaining nut locked in the full forward position (“Dead Stall”). Reservoir should not drop below the red line on the reservoir housing.

NOTE: Dead Stalling is not necessary if Optional Stall nut was not used; just cycle tool.

Step 11

Re-lock the fill tool in out position. Lay tool on its left side and remove Bleed Plug (64). Top off reservoir by placing a few drops of oil in hole and wait for air bubbles to escape. Push a pin or a scribe into hole to check for trapped air bubbles. Replace plug. (Fig. 7)

Step 12

Unlock the fill tool and cycle tool as in step 10. Reservoir may drop slightly. If so, repeat step 11 until when you touch the fill tool handle it has no pressure against it and it drops out of the lock position, and the plunger does not drop when tool is cycled. NOTE: This usually requires 3 to 4 times topping off.

Step 13

Remove fill tool and stall nut (if used). Install a nose assembly and pull several fasteners to test function.

WARNING - Failure to re-lock the fill tool will result in oil being ejected from the head under pressure during the topping off of the reservoir. Severe personal injury may result.

FIG. 7

FIG. 8

WARNING: Air pressure MUST be set to 20 to 40 psi to prevent possible injury from high pressure spray. If plug (71) is removed, fill bottle must be in place before cycling tool.

120824 STALL NUT

FILL TOOL 112465

RED LINE INDICATOR

255

HUCK

U.S. PAT. 4597263

Page 13

MODEL 255 TOOL HUCK FASTENERS

ASSEMBLY

DRAWING

FIG. 9

910

5 4 3

93 21

(31) PISTON ASSEMBLY

(22) RETURN GLAND ASSEMBLY

(Note direction of polyseal)

(90) PULL GLAND ASSEMBLY

51 50 49

45 44 43 4542 41

81 80

79 64 65

77 76 75

(54) GLAND ASSEMBLY

2588878685847225

SECTION A-A

25726571706564

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MODEL 255 TOOL HUCK FASTENERS

50 501460 Quad Ring 1 51 100315 Piston, Air 1 52 112414 Piston Rod 1 53 115556 Cylinder Assembly 1 54 116173 Gland Assembly 1 55 500786 O-ring 1 56 501074 Quad Ring 1 57 501090 Back-up Ring 1 58 500784 O-ring 1 59 505939 Retaining Ring 1 60 123904 Spacer 1 61 506611 Polyseal 1 62 123903 Gland 1 63 500424 Screw 2 64 100309 Bleed Plug 3 65 505438 O-ring 4 66 120005 Throttle Arm 1 67 116916 Screw 1 68 125656 Guard 1 69 500102 Screw, Cap 4 70 120204 Plug 1 71 111068 Plug 1 72 505446 O-ring 3 73 120203 Pin 1 74 120129 Screw 1 75 100874 Spring 1 76 111067 Guide 1 77 502929 Ball 1 78 111139 Seat 1 79 112405 Reservoir Plunger 1 80 501408 Quad Ring 1 81 112403 Housing/Spacer Assembly 1 82 505864 Spring 2 83 114530 Plug 1 84 505863 Spring 1 85 120127 Sleeve 1 86 120128 Valve Guide 1 87 502506 Ball 1 88 114528 Seat 1 89 126079 Head Assembly 1 90 112501 Pull Gland Assembly 1 91 123138 Wiper Housing 1 92 126081 Front Gland 1 93 126085 Rear Gland 1

1 125641 Handle & Sleeve Assembly 1 2 125643 Cable 1 3 124333 Trigger 1 4 505496 Trigger Pin 1 5 500621 Roll Pin 1 6 108279 Pintail Tube 1 7 110670 Stop 1 8 117824 Retaining Nut 1

9 505894 Wiper Seal 1 10 506160 Polyseal 1 11 126083 Piston, Pull 1 12 113251 Back-up Ring 2 13 500851 O-ring 1 14 500823 O-ring 1 15 126088 Back-up Ring 1 16 505887 O-ring 1 17 113253 Back-up Ring 1 18 505791 O-ring 1 19 113754 Back-up Ring 1 20 112491 End Cap 1 21 124211 Pintail Deflector 1 22 112502 Return Gland Assembly 1 23 112427 Return Gland 1 24 500776 O-ring 2 25 501082 Back-up Ring 6 26 500778 O-ring 1 27 501084 Back-up Ring 3 28 112426 Gland 1 29 501087 Back-up Ring 1 30 500781 O-ring 1 31 118865 Hydraulic Piston Assembly 1 32 117773 Screw 1 33 503768 O-ring 1 34 117774 Piston, Hydraulic 1 35 500773 O-ring 1 36 115505 Throttle Valve 1 37 504408 O-ring 2 38 115436 Air Hose Assembly 1 39 504407 O-ring 1 40 116272 Spring 1 41 121241 Self-locking Nut 1 42 116585 Muffler End Cap 1 43 115554 Muffler 1 44 500777 O-ring 1 45 504127 Screw, Button Head 3 46 125724-2 Gasket 1 47 505025 Retaining Ring 1 48 500873 O-ring 1 49 111959 Cylinder Head 1

ITEM PART# DESCRIPTION QTY

Page 15

MODEL 255 TOOL HUCK FASTENERS

Always check out the simplest possible cause of a malfunction first. For example, an air hose not connected. Then proceed logically, eliminating each possible cause until the cause is located. Where possible, substitute known good parts for suspected bad parts. Use TROUBLESHOOTING CHART as an aid in locating and correcting malfunction.

NOTE:

“Piston drift” is when the air piston is in the down position, but the hydraulic pull piston is not in the full follward position. This causes an out of sequence condition.

1 Tool fails to operate when trigger is depressed.

a) Air line not connected b) Throttle Valve O-rings (37 & 39), worn or

damaged.

c) Throttle Valve Cable (2) is broken.

2 Tool does not complete fastener installation and

break pintail.

a) Air pressure too low b) Air Piston Quad-ring (50) worn or damaged. c) Reservoir empty or low, refer to Fill and Bleed

section.

d) Air in hydraulic system, refer to Fill and Bleed

section. e) Reservoir Springs (82) worn or damaged f) Check for piston drift

3 Pintail stripped and/or swaged collar not ejected.

a) Check for broken or worn jaws in nose assembly,

refer to nose assembly data sheet. b) Check for loose Retaining Nut (8) c) Check for piston drift.

4 Tool has piston drift.

a) Loose collet crashing into the front of the anvil,

this causes the relief valve to open allowing the

piston to drift. Tighten the collet and refer to Fill

and Bleed section. b) Worn or damaged Return Pressure Relief Valve

in tool, inspect Seat (88), O-ring (72), Back-up

Rings (25), Steel Ball (87) and Valve Spring (84).

Replace if necessary. c) Worn or damaged Piston Assembly (31); inspect

O-ring (33), O-ring (35) and Back-up rings (27).

Replace if necessary.

5 Hydraulic fluid exhausts with air or leaks at base of

handle.

a) Worn or damaged Gland Assembly (54), inspect

Polyseal (61), O-rings (58 and 55), Quad-ring (56) and Back-up ring (57) replace if necessary.

6. Hydraulic fluid leaks at rear of Pull Piston (11)

a) Worn or damaged Rear Gland (93): Inspect

O-rings (16 and 18) and Back-up Rings (17 and

19). Replace if necessary.

7. Hydraulic fluid leaks at front of Pull Piston (11).

a) Worn or damaged Front Gland (92): Inspect Polyseal (10), O-ring (14) and Back-up Ring (15). Replace if necessary.

8. Pull Piston (11) will not return.

a) Throttle Valve (36) stuck: Lubricate O-rings (37 &

39).

b) Throttle Arm (66), Cable (2) or Trigger (3) binding.

9. Air leaks at air Cylinder Head (49).

a). Worn or damaged O-ring (48). Replace if

necessary.

ACCESSORIES

Stall Nut (Fig. 7) - 120824

Service Tool Kit - 126104

Includes:

Assembly Bullet (Fig.2) - 123111-1 Spacer (Fig. 2) - 123112-1

TROUBLESHOOTING

Page 16

MODEL 255 TOOL HUCK FASTENERS

----------------- S ERVICE NOTES ------------------

Page 17

----------------------------------------------------------------------------

1. CHEMICAL PRODUCT/COMPANY IDENTIFICATION

----------------------------------------------------------------------------

HYDROCLEAR(R) DEXRON(R) III/MERCON(R) Automatic Transmission Fluid

MSDS Code: ATFC0089 Revised: 14-Mar-2000

"HYDROCLEAR" is a registered trademark of Conoco. "DEXRON" is a registered trademark of General Motors Corp. "MERCON" is a registered trademark of Ford Motor Company.

Product Use: Automatic Transmission Fluid Conoco Blend Code: 46682

MANUFACTURER/DISTRIBUTOR Conoco Inc. P.O. Box 2197 Houston, TX 77252 PHONE NUMBERS Product Information: 1-281-293-5550 Transport Emergency: CHEMTREC 1-800-424-9300 (U.S. & Canada) 703-527-3887 (elsewhere; call collect) Medical Emergency: 1-800-441-3637

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2. COMPOSITION/INFORMATION ON INGREDIENTS

-------------------------------------------------------------------------

COMPONENTS % Base oils >85 Proprietary additives <15

If oil mist is generated, exposure limits apply (see Section 8).

-------------------------------------------------------------------------

3. HAZARDS IDENTIFICATION

-------------------------------------------------------------------------

--- EMERGENCY OVERVIEW --APPEARANCE / ODOR Red liquid / mild petroleum hydrocarbon odor.

OSHA REGULATORY STATUS This material is classified as nonhazardous under OSHA Regulations.

HMIS RATING Health: 1; Flammability: 1; Reactivity: 0 ___________________________________

Potential Health Effects Primary Route of Entry: Skin The product, as with many petroleum products, may cause minor skin, eye, and lung irritation, but good hygienic practices can minimize these effects.

Normal use of this product does not result in generation of an oil mist. However if an oil mist is generated, overexposure can cause minor and reversible irritation to the eyes, skin, and especially the lungs. Proper personal protective equipment and sufficient ventilation can provide adequate protection.

Carcinogenicity Information None of the components present in this material at concentrations equal to or greater than 0.1% are listed by IARC, NTP, OSHA or ACGIH as a carcinogen.

------------------------------------------------------------------------

4. FIRST AID MEASURES

------------------------------------------------------------------------

INHALATION If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Call a physician.

SKIN CONTACT Wash skin thoroughly with soap and water. If irritation develops and persists, consult a physician.

EYE CONTACT In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Call a physician.

INGESTION Material poses an aspiration hazard. If swallowed, do not induce vomiting. Immediately give 2 glasses of water. Never give anything by mouth to an unconscious person. Call a physician. If vomiting occurs naturally, have victim lean forward to reduce the risk of aspiration.

Notes to Physicians Activated charcoal mixture may be administered. To prepare activated charcoal mixture, suspend 50 grams activated charcoal in 400 mL water and mix thoroughly. Administer 5 mL/kg, or 350 mL for an average adult.

---------------------------------------------------------------------------

5. FIRE FIGHTING MEASURES

---------------------------------------------------------------------------

Flammable Properties Flash Point (typical): 370 F (188 C) Flash Point (minimum): 351 F (177 C) Method: COC

NFPA Classification: Class IIIB Combustible Liquid. NFPA Rating: Health 0; Flammability 1; Reactivity 0

Extinguishing Media Water Spray, Foam, Dry Chemical, CO2.

Fire Fighting Instructions Water or foam may cause frothing. Use water to keep fire-exposed containers cool. Water may be used to flush spills away from exposures.

Products of combustion may contain carbon monoxide, carbon dioxide, and other toxic materials. Do not enter enclosed or confined space without proper protective equipment including respiratory protection.

---------------------------------------------------------------------------

6. ACCIDENTAL RELEASE MEASURES

---------------------------------------------------------------------------

Safeguards (Personnel) NOTE: Review FIRE FIGHTING MEASURES and HANDLING (PERSONNEL) sections before proceeding with clean-up. Use appropriate PERSONAL PROTECTIVE EQUIPMENT during clean-up.

Remove source of heat, sparks, and flame.

Initial Containment Dike spill. Prevent material from entering sewers, waterways, or low areas.

Spill Clean Up Recover free liquid for reuse or reclamation. Soak up with sawdust, sand, oil dry or other absorbent material.

---------------------------------------------------------------------------

7. HANDLING AND STORAGE

---------------------------------------------------------------------------

Handling (Personnel) Avoid breathing vapors or mist. Avoid contact with eyes. Avoid prolonged or repeated contact with skin. Wash thoroughly after handling. Wash contaminated clothing prior to reuse.

Handling (Physical Aspects) Close container after each use. Do not pressurize, cut, weld, braze, solder, grind, or drill on or near full or empty container. Empty container retains residue (liquid and/or vapor) and may explode in heat of a fire.

Storage Store in accordance with National Fire Protection Association recommendations. Store in a cool, dry place. Store away from heat, sparks and flames, oxidizers. Close container after each use.

---------------------------------------------------------------------------

8. EXPOSURE CONTROLS/PERSONAL PROTECTION

---------------------------------------------------------------------------

Engineering Controls VENTILATION Normal shop ventilation.

Personal Protective Equipment RESPIRATORY PROTECTION None normally required except in emergencies or when conditions cause excessive airborne levels of mists or vapors. Select appropriate NIOSH-approved respiratory protective equipment when exposed to sprays or mists. Proper respirator selection should be determined by adequately trained personnel and based on the contaminant(s), the degree of potential exposure, and published respirator protection factors.

PROTECTIVE GLOVES Should be worn when the potential exists for prolonged or repeated skin contact. NBR or neoprene recommended.

EYE PROTECTION Safety glasses with side shields.

OTHER PROTECTIVE EQUIPMENT Coveralls with long sleeves if splashing is probable.

Page 18

Applicable Exposure Limits If oil mist is generated, exposure limits apply. PEL (OSHA) : 5 mg/m3, 8 Hr. TWA TLV (ACGIH) : 5 mg/m3, 8 Hr. TWA, STEL 10 mg/m3

---------------------------------------------------------------------------

9. PHYSICAL AND CHEMICAL PROPERTIES

---------------------------------------------------------------------------

Physical Data Boiling Point: Not Available Vapor Pressure: Nil Vapor Density: >1 (Air=1.0) % Volatiles: Nil Evaporation Rate: Nil Solubility in Water: Insoluble Odor: Petroleum Hydrocarbon (mild). Form: Liquid. Color: Red. Specific Gravity: 0.87 @ 60 F (16 C) Density: 7.14 lb/gal

---------------------------------------------------------------------------

10. STABILITY AND REACTIVITY

---------------------------------------------------------------------------

Chemical Stability Stable.

Conditions to Avoid Heat, sparks, and flames.

Incompatibility with Other Materials Incompatible or can react with oxidizers.

Decomposition Normal combustion forms carbon dioxide; incomplete combustion may produce carbon monoxide.

Polymerization Polymerization will not occur.

---------------------------------------------------------------------------

11. TOXICOLOGICAL INFORMATION

---------------------------------------------------------------------------

Animal Data Mouse skin painting studies have shown that highly refined petroleum lube base oils similar to ingredients in this product have not caused skin tumors.

---------------------------------------------------------------------------

12. ECOLOGICAL INFORMATION

---------------------------------------------------------------------------

Ecotoxicological Information No specific aquatic data available for this product.

---------------------------------------------------------------------------

13. DISPOSAL CONSIDERATIONS

---------------------------------------------------------------------------

Waste Disposal Treatment, storage, transportation, and disposal must be in accordance with applicable Federal, State/Provincial, and Local regulations. Do not flush to surface water or sanitary sewer system.

Container Disposal Empty drums should be completely drained, properly bunged, and promptly shipped to the supplier or a drum reconditioner. All other containers should be disposed of in an environmentally safe manner.

---------------------------------------------------------------------------

14. TRANSPORTATION INFORMATION

---------------------------------------------------------------------------

Shipping Information DOT: Not regulated. ICAO/IMO: Not restricted.

---------------------------------------------------------------------------

15. REGULATORY INFORMATION

---------------------------------------------------------------------------

U.S. Federal Regulations OSHA HAZARD DETERMINATION This material is not known to be hazardous as defined by OSHA's Hazard Communication Standard, 29 CFR 1910.1200.

CERCLA/SUPERFUND Not applicable; this material is covered by the CERCLA petroleum exclusion.

SARA, TITLE III, 302/304 It is possible material may contain extremely hazardous substances at concentrations below 1.0% so that a large-enough spill could warrant an Emergency Release Report.

SARA, TITLE III: 311/312 HAZARD CLASSIFICATIONS Acute: No Chronic: No Fire: No Reactivity: No Pressure: No

SARA, TITLE III, 313 This material is not known to contain any chemical(s) at a level of 1.0% or greater (0.1% for carcinogens) on the list of Toxic Chemicals and subject to release reporting requirements. TSCA Material and/or components are listed in the TSCA Inventory of Chemical Substances (40 CFR 710).

RCRA This material has been evaluated for RCRA characteristics and does not meet hazardous waste criteria if discarded in its purchased form. Because of product use, transformation, mixing, processing, etc., which may render the resulting material hazardous, it is the product user's responsibility to determine at the time of disposal whether the material meets RCRA hazardous waste criteria.

CLEAN WATER ACT The material contains the following ingredient(s) which is considered hazardous if spilled into navigable waters and therefore reportable to the National Response Center (1-800-424-8802). Ingredient(s): Petroleum Hydrocarbons Reportable Quantity: Film or sheen upon, or discoloration of any water surface

CLEAN WATER ACT This material is not known to contain hazardous substances in sufficient quantity to make it subject to CERCLA regulations.

State Regulations (U.S.) CALIFORNIA "PROP 65" This material may contain trace amount(s) of an ingredient(s) known to the State of California to cause cancer, birth defects, or other reproductive harm. Read and follow all label directions.

PENNSYLVANIA WORKER & COMMUNITY RIGHT TO KNOW ACT This material is not known to contain any ingredient(s) subject to the Act. Nonhazardous ingredient information is withheld as a trade secret in accordance with Section 11 of the Act.

Canadian Regulations This is not a WHMIS Controlled Product.

--------------------------------------------------------------------------# 16. OTHER INFORMATION

---------------------------------------------------------------------------

NOTE: This product or any other hydrocarbon-based lubricant should not be used in non-diaphragm compressors that produce "breathing air" unless the outlet is monitored continuously for carbon monoxide. These lubricants can produce carbon monoxide when subjected to high temperatures. ________________ The data in this Material Safety Data Sheet relates only to the specific material designated herein and does not relate to use in combination with any other material or in any process.

Responsibility for MSDS : MSDS Coordinator Address : Conoco Inc. > : PO Box 2197 > : Houston, TX 77252 Telephone : 1-281-293-5550 Web Site : www.Conoco.com

Page 19

HUCK FASTENERS

LIMITED WARRANTIES

Tooling Warranty: Huck warrants that tooling and other items (excluding fasteners, and hereinafter referred as "other items") manufactured by Huck shall be free from defects in workmanship and materials for a period of ninety (90) days from the date of original purchase.

Warranty on "non standard or custom manufactured products": With regard to non-standard products or

custom manufactured products to customer's specifications, Huck warrants for a period of ninety (90) days from the date of purchase that such products shall meet Buyer's specifications, be free of defects in workmanship and materials. Such warranty shall not be effective with respect to non-standard or custom products manufactured using buyer-supplied molds, material, tooling and fixtures that are not in good condition or repair and suitable for their intended purpose.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. HUCK MAKES NO OTHER WARRANTIES AND EXPRESSLY DISCLAIMS ANY OTHER WARRANTIES, INCLUDING IMPLIED WARRANTIES AS TO MERCHANTABILITY OR AS TO THE FITNESS OF THE TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS FOR ANY PARTICULAR PURPOSE AND HUCK SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING FROM THE USE OF SUCH TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS OR BREACH OF WARRANTY OR FOR ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Huck's sole liability and Buyer's exclusive remedy for any breach of warranty shall be limited, at Huck's option, to replacement or repair, at FOB Huck's plant, of Huck manufactured tooling, other items, nonstandard or custom products found to be defective in specifications, workmanship and materials not otherwise the direct or indirect cause of Buyer supplied molds, material, tooling or fixtures. Buyer shall give Huck written notice of claims for defects within the ninety (90) day warranty period for tooling, other items, nonstandard or custom products described above and Huck shall inspect products for which such claim is made.

Tooling, Part(s) and Other Items not manufactured by Huck.

HUCK MAKES NO WARRANTY WITH RESPECT TO THE TOOLING, PART(S) OR OTHER ITEMS MANUFACTURED BY THIRD PARTIES. HUCK EXPRESSLY DISCLAIMS ANY WARRANTY EXPRESSED OR IMPLIED, AS TO THE CONDITION,

DESIGN, OPERATION, MERCHANTABILITY OR FITNESS FOR USE OF ANY TOOL, PART(S), OR OTHER ITEMS THEREOF NOT MANUFACTURED BY HUCK. HUCK SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING FROM THE USE OF SUCH TOOLING, PART(S) OR OTHER ITEMS OR BREACH OF WARRANTY OR FOR ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

The only warranties made with respect to such tool, part(s) or other items thereof are those made by the manufacturer thereof and Huck agrees to cooperate with Buyer in enforcing such warranties when such action is necessary.

Huck shall not be liable for any loss or damage resulting from delays or nonfulfillment of orders owing to strikes, fires, accidents, transportation companies or for any reason or reasons beyond the control of the Huck or its suppliers.

Huck Installation Equipment

Huck International, Inc. reserves the right to make changes in specifications and design and to discontinue models without notice.

Huck Installation Equipment should be serviced by trained service technicians only.

Always give the Serial Number of the equipment when corresponding or ordering service parts.

Complete repair facilities are maintained by Huck International, Inc. Please contact one of the offices listed below.

Eastern One Corporate Drive Kingston, New York 12401-0250 Telephone (845) 331-7300 FAX (845) 334-7333

Canada 6150 Kennedy Road Unit 10, Mississauga, Ontario, L5T2J4, Canada. Telephone (905) 564-4825 FAX (905) 564-1963

Out

side USA and Canada Contact your nearest Huck International Office, see back cover.

In addition to the above repair facilities, there are Authorized Tool Service Centers (ATSC's) located throughout the United States. These service centers offer repair services, spare parts, Service Parts Kits, Service Tools Kits and Nose Assemblies. Please contact your Huck Representative or the nearest Huck office listed on the back cover for the ATSC in your area.

Page 20

HUCK FASTENERS

Huck Acceptance is World-wide

Huck Fastener maintains company offices throughout the United States and

Canada with subsidiary offices in many other countries. Sales engineers and

systems specialists located in your area can help in solving your fastener problems.

Huck Fasteners world-wide locations:

Americas

Huck International, Inc.

World Headquarters

3724 East Columbia Tucson, AZ 85714 800-234-4825 520-747-9898 FAX: 520-748-2142

Huck International, Inc.

Aerospace Fastener Division

3724 East Columbia Tucson, AZ 85714 800-234-4825 520-747-9898 FAX: 520-748-2142

Huck International, Inc.

Aerospace Fastener Division

PO Box 5268 900 Watsoncenter Rd. Carson, CA 90749 800-421-1459 310-830-8200 FAX: 310-830-1436

Huck International, Inc.

Industrial Fastener Division

PO Box 8117 8001 Imperial Drive Waco, TX 76714-8117 800-388-4825 254-776-2000 FAX: 254-751-5259

Huck International, Inc. Inst

allation Systems

Division

1 Corporate Drive Kingston, NY 12401 800-431-3091 845-331-7300 FAX: 845-334-7333 www.hucktools.com

Huck International Ltd.

6150 Kennedy Road, Unit 10 Mississagua, Ontario L5T2J4 Canada 905-564-4825 FAX: 905-564-1963

Huck International, Inc.

Avenida Parque Lira. 79-402 Tacubaya Mexico, D.F. C.P. 11850 FAX: 525-515-1776 TELEX: 1173530 LUKSME

Far East

Huck Australia, Pty. Ltd.

Private Bag 6 Rowville, Victoria Australia 3178 03-764-5500 Toll Free: 008-335-030 FAX: 03-764-5510

Europe

Huck International Ltd.

Unit C, Stafford Park 7 Telford, Shropshire England TF3 3BQ 0952-290011 FAX: 0952-290459

Huck S.A.

Clos D’Asseville BP4 95450 Us Par Vigny France 33-1-30-27-9500 FAX: 33-1-34-66-0600