Huck 256BT Instruction Manual

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Page 1

07-10-2013

HK1109

INSTRUCTION MANUAL

256BT

PNEUDRAULIC INSTALLATION TOOL

Page 2

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

Page 3

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

SAFETY

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

SPECIFICATIONS

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

PRINCIPLE OF OPERATION

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

OPERATING INSTRUCTIONS

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

MAINTENANCE

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

DISASSEMBLY

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

ASSEMBLY

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

FILL AND BLEED

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13

ASSEMBLY DRAWINGS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15

PARTS LIST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-16

MEASURING TOOL STROKE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

ACCESSORIES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

ONTENTS

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256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

I. GENERAL SAFETY RULES:

1. A half hour long hands-on training session with qualified personnel is recommended before using Huck equipment.

2. Huck equipment must be maintained in a safe working condition at all times. Tools and hoses should be inspected at the beginning of each shift/day for damage or wear. Any repair should be done by a qualified repairman trained on Huck procedures.

3. For multiple hazards, read and understand the safety instructions before installing, operating, repairing, maintaining, changing accessories on, or working near the assembly power tool. Failure to do so can result in serious bodily injury.

4. Only qualified and trained operators should install, adjust or use the assembly power tool.

5. Do not modify this assembly power tool. This can reduce effectiveness of safety measures and increase operator risk.

6. Do not discard safety instructions; give them to the operator.

7. Do not use assembly power tool if it has been damaged.

8. Tools shall be inspected periodically to verify all ratings and markings required, and listed in the manual, are legibly marked on the tool. The employer/operator shall contact the manufacturer to obtain replacement marking labels when necessary. Refer to assembly drawing and parts list for replacement.

9. Tool is only to be used as stated in this manual. Any other use is prohibited.

10. Read MSDS Specifications before servicing the tool. MSDS specifications are available from the product manufacturer or your Huck representative.

11.Only genuine Huck parts shall be used for replacements or spares. Use of any other parts can result in tooling damage or personal injury.

12.Never remove any safety guards or pintail deflectors.

13.Never install a fastener in free air. Personal injury from fastener ejecting may occur.

14.Where applicable, always clear spent pintail out of nose assembly before installing the next fastener.

15.Check clearance between trigger and work piece to ensure there is no pinch point when tool is activated. Remote triggers are available for hydraulic tooling if pinch point is unavoidable.

16.Do not abuse tool by dropping or using it as a hammer. Never use hydraulic or air lines as a handle or to bend or pry the tool. Reasonable care of installation tools by operators is an important factor in maintaining tool efficiency, eliminating downtime, and preventing an accident which may cause severe personal injury.

17.Never place hands between nose assembly and work piece. Keep hands clear from front of tool.

18.Tools with ejector rods should never be cycled with out nose assembly installed.

19.When two piece lock bolts are being used always make sure the collar orientation is correct. See fastener data sheet for correct positioning.

II. PROJECTILE HAZARDS:

1. Risk of whipping compressed air hose if tool is pneudraulic or pneumatic.

2. Disconnect the assembly power tool from energy source when changing inserted tools or accessories.

3. Be aware that failure of the workpiece, accessories, or the inserted tool itself can generate high velocity projectiles.

4. Always wear impact resistant eye protection during tool operation. The grade of protection required should be assessed for each use.

5. The risk of others should also be assessed at this time.

6. Ensure that the workpiece is securely fixed.

7. Check that the means of protection from ejection of fastener or pintail is in place and operative.

8. There is possibility of forcible ejection of pintails or spent mandrels from front of tool.

III. OPERATING HAZARDS:

1. Use of tool can expose the operator’s hands to hazards including: crushing, impacts, cuts, abrasions and heat. Wear suitable gloves to protect hands.

2. Operators and maintenance personnel shall be physically able to handle the bulk, weight and power of the tool.

3. Hold the tool correctly and be ready to counteract normal or sudden movements with both hands available.

4. Maintain a balanced body position and secure footing.

5. Release trigger or stop start device in case of interruption of energy supply.

6. Use only fluids and lubricants recommended by the manufacturer.

7. Avoid unsuitable postures, as it is likely for these not to allow counteracting of normal or unexpected tool movement.

8. If the assembly power tool is fixed to a suspension device, make sure that fixation is secure.

9. Beware of the risk of crushing or pinching if nose equipment is not fitted.

IV. REPETITIVE MOTION HAZARDS:

1. When using assembly power tool, the operator can experience discomfort in the hands, arms, shoulders, neck or other parts of the body.

2. When using tool, the operator should adopt a comfortable posture while maintaining a secure footing and avoid awkward or off balanced postures.

3. The operator should change posture during extended tasks to help avoid discomfort and fatigue.

4. If the operator experiences symptoms such as persistent or recurring discomfort, pain, throbbing, aching, tingling, numbness, burning sensations or stiffness, these warnings should not be ignored. The operator should tell the employer and consult a qualified health professional.

V. ACCESSORIES HAZARDS:

1. Disconnect tool from energy supply before changing inserted tool or accessory.

2. Use only sizes and types of accessories and consumables that are recommended. Do not use other types or sizes of accessories or consumables.

VI. WORKPLACE HAZARDS:

1. Be aware of slippery surfaces caused by use of the tool and of trip hazards caused by the air line or hydraulic hose.

2. Proceed with caution while in unfamiliar surroundings; there could be hidden hazards such as electricity or other utility lines.

3. The assembly power tool is not intended for use in potentially explosive environments.

4. Tool is not insulated against contact with electrical power.

5. Ensure there are no electrical cables, gas pipes, etc., which can cause a hazard if damaged by use of the tool.

VII. NOISE HAZARDS:

1. Exposure to high noise levels can cause permanent, disabling hearing loss and other problems such as tinnitus, therefore risk assessment and the implementation of proper controls is essential.

2. Appropriate controls to reduce the risk may include actions such as damping materials to prevent workpiece from ‘ringing’.

3. Use hearing protection in accordance with employer’s instructions and as required by occupational health and safety regulations.

4. Operate and maintain tool as recommended in the instruction handbook to prevent an unnecessary increase in the noise level.

5. Select, maintain and replace the consumable / inserted tool as recommended to prevent an unnecessary increase in noise.

6. If the power tool has a silencer, always ensure that it is in place and in good working order when the tool is being operated.

VIII. VIBRATION HAZARDS:

1. Exposure to vibration can cause disabling damage to the nerves and blood supply to the hands and arms.

2. Wear warm clothing when working in cold conditions and keep hands warm and dry.

3. If numbness, tingling, pain or whitening of the skin in the fingers or hands, stop using the tool, tell your employer and consult a physician.

4. Support the weight of the tool in a stand, tensioner or balancer in order to have a lighter grip on the tool.

IX. PNEUMATIC / PNEUDRAULIC TOOL SAFETY INSTRUCTIONS:

1. Air under pressure can cause severe injury.

2. Always shut off air supply, drain hose of air pressure and disconnect tool from air supply when not in use, before changing accessories or when making repairs.

3. Never direct air at yourself or anyone else.

4. Whipping hoses can cause severe injury, always check for damaged or loose hoses and fittings.

5. Cold air should be directed away from hands.

6. Whenever universal twist couplings (claw couplings) are used, lock pins shall be installed and whipcheck safety cables shall be used to safeguard against possible hose to hose or hose to tool connection failure.

7. Do not exceed maximum air pressure stated on tool.

8. Never carry an air tool by the hose.

GLOSSARY OF TERMS AND SYMBOLS:

- Product complies with requirements set forth by the relevant European directives.

- READ MANUAL prior to using this equipment.

- EYE PROTECTION IS REQUIRED while using this equipment.

- HEARING PROTECTION IS REQUIRED while using this equipment.

Notes: are reminders of required procedures.

Bold, Italic type and underlining

: emphasizes a specific instruction.

AFETY

NSTRUCTIONS

CAUTIONS: show conditions that will damage equipment and or structure.

WARNINGS: Must be understood to avoid severe personal injury.

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256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

Power Source: Huck POWERIG Hydraulic Unit

Hydraulic Fluid: ATF meeting DEXRON III, DEXRON IV,

MERCON, Allison C-4 or equivalent specifications. Fire resistant hydraulic fluid may also be used and is required to comply with OSHA regulation 1926.302 paragraph (d): "the fluid used in hydraulic power tools shall be fire resistant fluid approved under schedule 30 of the US Bureau of Mines, Department of Interior, and shall retain its operating characteristics at the most extreme temperatures to which it will be exposed."

• Stroke: 1.275 in (3.24 cm)

• Weight: 11 lbs (5 kg)

• Max Air Pressure: 90 psi (6.2 BAR)

• Max Flow Rate: 22.4 scfm

• Capacity: 6700 lbs (29.8 kN) @ 90 psi (6.2 BAR)

• Speed/Cycles: 30 per minute

• Max Operating Temp: 125°F (52°C)

PECIFICATIONS

1.50

(38)

INCHES

(mm)

4°

6.99

(177.6)

HUCK

.93

(23.7)

256BT

1.86

(47.3)

14.85

(377.2)

6.15

(156.3)

6.13

(155.6)

3.98

(101.1)

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256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

When the trigger is depressed the throttle valve moves to down position, 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 spindle 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.

RINCIPLE

PERATION

PERATING

NSTRUCTIONS

For safe operation. Please read completely

WARNINGS:

●To avoid severe personal injury: Wear approved eye and ear protection.

● Be sure of adequate clearance for Operator’s hands before proceeding with fastener installation.

ENERAL

Operators should receive training from qualified personnel.

Do not bend tool to free if stuck.

Tool should only be used to install fasteners. NEVER use as a jack/spreader or hammer.

BOBTAIL® Fastener Installation:

Place pin in workpiece and place collar over pin. See WARNING. (If Collar has only one tapered end, that end MUST

be out toward tool; not next to

sheet.) Hold pin and push nose assembly onto pin

protruding through collar until nose anvil touches collar. Depress trigger and hold until collar is swaged and pintail breaks. Release trigger. Tool will go into its return stroke. Tool/nose are ready for next installation cycle.

• Length of tool increases during fastener

installation. Allow adequate tool and anvil clearance before installing fasteners.

• Check pin for correct grip. Place pin in work

hole.

• Place collar over pin. See WARNINGS. If collar

has only one tapered end, that end should be outward toward tool.

• Hold pin in hole. Push tool onto pin protruding

from collar until anvil touches collar.

• Move hands away from pin and structure. Keep

hands away from front of tool during operation. Tool anvil advances forward.

• Hold tool at right angle (90 degrees) to work.

Press and hold trigger down until collar is swaged.

• Release trigger. Tool returns to starting position.

• Tool is ready for next installation cycle.

WARNING: Do not pull on a pin without placing fastener/collar in a workpiece, and also, collar chamfer MUST be out toward tool. These conditions cause pin to eject with great velocity and force when the pintail breaks off or teeth/grooves strip. This may cause severe personal injury.

CAUTIONS: Remove excess gap from between the sheets. This permits enough pintail to emerge from collar for ALL jaw teeth to engage with pintail. If ALL teeth do not engage properly, jaws will be damaged.

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256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

ENERAL

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 lit 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 includes consumable parts and should be available at all times. Other components, as experience dictates, should also be available.

AILY

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.

AINTENANCE

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

CAUTIONS:

●Consult MSDS before servicing tool.

●Keep dirt and other material out of hydraulic system.

●Separated parts most be kept away from dirty work surfaces.

●Dirt/debris in hydraulic fluid causes Dump Valve failure in Tool and in POWERIG® Hydraulic Unit’s valves.

CAUTION: Do not use TEFLON®* tape on pipe threads. Pipe threads may cause tape to shred resulting in tool malfunction. (Slic-Tite is available in stick form as Huck P/N 503237.)

CAUTION: Always replace seals, wipers, and back-up rings when tool is disassembled for any reason.

Note: See SS

PECIFICATIONS

PECIFICATIONS for fluid type. Dispose of

fluid in accordance with local environmental regulations. Recycle steel, aluminum, and plastic parts in accordance with local lawful and safe practices.

Page 8

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

ISASSEMBLY

NOTE: The following procedure is for complete disassembly of tool. Disassemble only those components necessary to replace damaged Orings, 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.

3. Insert Fill Tool part no. 112465 through reservoir housing and screw into Reservoir Plunger (42) locking it in the out position. Figure 1

4. Unscrew Cap Screws (32) with 5/32 hex key. Carefully lift Head (9) straight up from Handle (1), remove Pull Gland Assy (31) and Return Gland Assy (15) from separated Head and Handle assembly. Remove seals from glands. Figure 1

5. Unscrew Plug (57) of return Pressure Relief Valve from front of head. Remove Spring (56), Valve Guide (54), Sleeve (55) and Steel Ball (53). A small magnet is helpful. Figure 1

6. Unscrew Bleed Plug (33). Hold over waste oil container and release fill tool slowly. Figure 1

7. Unscrew Reservoir Housing (40) from head. Remove two Springs (39). Slide Reservoir Plunger (42) from head. Remove spacer and Quad Ring (41). A pick may be used to remove the quad ring. Figure 1

8. Unscrew Plug (50) of reservoir check valve from side of head. Remove Spring (45), Check Valve Guide (44) and Stainless Steel Check Valve Ball (43). Figure 1

9. If Check Valve Seat (52) is damaged contact your Huck representative. If Seat (52a) is damaged it can be removed by using the following procedure. NOTE: If seat is taken

out it cannot be reused; it must be replaced. Figure 9

10. Seat Assy (52) Removal: NOTE: All parts in the reservoir check valve must be removed before Plug (51) can be removed. Using a

3/16 Allen wrench, remove Screw (46). Insert a #10 screw in the thread of Plug (51). Pull to remove. Using optional Seat Removal Tool p/n 126136 or a small drift and hammer, from the rear side of the head, drive Seat Assy (52) out towards the front of the head. Figure 9

11. Unscrew Cylinder Cap (13) from Head (9) with 1 11/16 open end wrench. Unscrew Cylinder Cap (13) from Head (9) with with 1 11/16 open end wrench.

12. Remove Piston (11) through rear of tool.

NOTE: Piston should push out front and rear gland assemblies.

13. Remove two Screws (34) from Throttle Arm Guard (37) and remove guard.

14. Remove Screw (35) from Throttle Arm (36). Remove throttle arm. Pull Throttle Valve (17a) out of cylinder. Remove Spring (17d). Figure 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 (36), and pull cable out of handle.

Figure 9

16. Remove Bleed Plug (33) from handle. Figure 1

FIG. 1

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.

Lock-out Position

FILL TOOL

112465

HUCK

256BT

U.S. PA

SPACER

4239(2)4140

. 4597263

56 57

4344

(4)

55 53 54

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256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

17. Hold tool inverted in vice. Unscrew four Button Head Screws (18) with 1/8 hex key. (Fig. 3)

18. Remove Muffler End Cap (20), Bottom Exhaust Gasket (23), Muffler (21) and O-ring (22). (Fig. 3)

19. Remove Retaining Ring (24) from Cylinder Assembly (28). (Fig. 3) NOTE: Tap cylinder head down into cylinder for easier removal of retaining ring.

20. Screw Button Head Screws (18) into Cylinder Head (25a). 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 (19) with a 9/16 socket and extension and, with 7/64 hex key, remove piston Screw (30b). (Fig. 4 & 9)

22. Return cylinder and handle to upside down position, and secure in a vise.

23. Grip Self-locking Nut (19) under Air Piston (26) with pliers and pull piston and rod assembly from handle and cylinder assembly. (Fig. 3 & 4)

24. With a 1 3/8 socket and extension, remove Gland Assembly (29). Handle and cylinder will now separate. (Fig. 3)

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

26. To remove Polyseal (29e) from Gland Assembly (29). Remove Retaining Ring (29k) and Spacer (29a). (Fig. 9)

ISASSEMBLY

ISASSEMBLY (continued)

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

CAUTION: A plastic or wooden drift must be used to avoid damaging the handle bore.

FIG. 3

25a

25b

26b 26a

Page 10

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

Clean components with mineral spirits, or similar solvent. Inspect for wear/damage and replace as necessary. Replace all seals of disassembled components. Use O-rings, Quad rings and Back-up rings in Service Parts Kit, P/N 256BTKIT Smear LUBRIPLATE 130AA or PARKER-O-LUBE 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 (28) on handle with Timing Pin positioned in matching hole. Assemble Gland Assembly (29) and screw it into handle. (Fig. 9) Torque to 100 120 ft. lbs. using 1 3/8 socket wrench.

2. Push Air Piston/Rod assembly with Quad Ring (26b) in place into air cylinder until it reaches top of cylinder. (Fig. 3)

3. Turn tool upright. Install Hydraulic Piston Assembly (30) (with O-ring (30c) and Back-up Rings (30d) in place) in handle. Press in from top of handle taking care not to damage seals. (Fig. 4)

4. Push Screw (30b) with O-ring (30e) in place through Hydraulic Piston (30a) and screw into top of piston rod. Hold Nut (19) with 9/16 socket and extension and torque Screw (30b) using 7/64 hex key to 55 - 60 in. lbs.

5. Hold handle in vise with bottom facing up. Push Cylinder Head (25a) with O-ring (25b) in place squarely into cylinder. Install Retaining Ring (24). (Fig. 3 & 9)

6. Position O-ring (22) and Muffler (21) on center of Cylinder Assy (25). Place Gasket (23) on Cylinder Assembly (28). NOTE: Lip must face Muffler End Cap (20). Place Muffler End Cap (20) on top of Gasket (23), and secure with 3 Button Head Screws (18) using 1/8 hex key. (Fig. 3)

7. Turn tool upright. Drop Spring (17d) into Throttle Valve hole in cylinder. Push Throttle Valve (17a) with O-rings (17b & 17c) in place into cylinder. (Fig.

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 (36) onto ball end of throttle cable. Swing arm until other end fits over throttle valve. Push Screw (35) through Throttle Arm (36). Tighten with 5/32 hex key.

10. If Air Hose Assembly (38) was removed, reinstall in Cylinder Assembly (28).

11. {If Seat Assy (52) is being replaced}: Push Plug (51) (with O-ring 48 & Back-up Ring 47 in place) into head. Install Screw (46). (Fig. 9)

12. Install O-ring (52c) and Back-up Rings (52b ) onto Seat (52a). Drive Seat Assy (52) in using soft drift taking care not to damage Relief Valve Ball (53) surface. (Fig. 9, Section A-A)

13. Assemble Pull Piston (11a) with new Seals (11b & 11c). Lubricate with LUBRIPLATE or PARKER SUPER-O-LUBE and install. (Fig. 9 & 10)

14. Push Front Gland Assy (10) with all seals, housing and wiper in place (Figure 2) over Assembly Bullet and onto Pull Piston Assy (11). (Fig. 9 & 10)

SSEMBLY

CAUTION: Do NOT scratch piston rod.

WARNING: Do not omit any seals during servicing, leaks will result and personal injury may occur.

WARNING: Tool must be fully assembled with all components included.

FIG. 4

30 Piston Assembly

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256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

15. Install O-rings (12d & 12b) and Back-up Rings (12e & 12c) on Rear Gland (12a). Push complete assembly into head. Screw in End Cap (13) and tighten. (Fig. 9 & 10)

16. Install O-ring (48) & Back-up Ring (47) on Plug (57). Install Ball (53), Valve Guide (54), Sleeve (55), Spring (56) and Plug (45) into head. (Fig. 1 & 9)

17. Install O-ring (49) on Plug (50). Install Check Valve Ball (43), Check Valve Guide (44), Spring (45) and Plug (50) into head.

18. Push Pintail Deflector (14) onto barbed end of Pull Piston (11a). (Fig. 9)

19. Place O-rings (33b) on Bleed Plugs (33a) and screw assemblies into Handle (Qty. 1) and Cylinder Head (Qty. 2). (Fig. 9)

20. Install O-rings (31c & 31e) & Back-up Rings (31b & 31d) on Pull Gland (31a). Install O-rings (15c & 15d) and Back-up Rings (15b & 15e) on Return Gland (15a). Push Gland Assemblies (15 & 31) into handle. Push Head (9) down on glands. Place tool in a vise, head down, and install 4 Screws (32) and torque to 170 inch pounds. (Fig. 5)

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

SSEMBLY

SSEMBLY (continued)

FIG. 5

32(4)

Page 12

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

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 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 (57) and (50) and all guides, springs and balls from ports in head. Reinstall Plug (57) 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)

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.

FIG. 7

FILL

POINT

120337

Fill Bottle

Assembly

FIG. 6

FIG. 8

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.

WARNING: Air pressure MUST be set to 20 to 40 psi to prevent possible injury from high pressure spray. If plug (50) is removed, fill bottle must be in place before cycling tool.

ILL

AND

LEED

Stall Nut

120824

Fill Tool

256/257

HUCK

Red Line

Indicator

44 43

5355

Page 13

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

Step 8

Install the check valve Ball (43), Guide (44) and Spring (45). Replace the Plug (50). (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 (57). Prior to removing Plug (57), it is advisable to back out setscrew inside of plug by approximately 1/2 turn counterclockwise. (See Figure 8a). This ensures that the Piston will remain in fullforward position. Install Relief Valve Ball (53), Guide (54), Sleeve (55) and Spring (56). Replace the Relief Valve Plug (57) and, after bleeding, re-tighten setscrew.

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 side with the reservoir on the high side, and remove Bleed Plug (33) from the reservoir side. 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. (Figs. 7 & 8a)

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.

FIG. 8a

ILL

AND

LEED

LEED (CONTINUED)

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.

WARNING

Air pressure MUST be set to 20 to 40 psi to prevent possible injury from high pressure spray. If plug (78) is removed, fill bottle must be in place before cycling tool.

33 - Bleed

Plug

57 - Relief Valve Plug

Using a 3/32 Allen wrench, loosen setscrew inside Plug by approx. 1/2 turn.

53 - Relief Valve Ball

SECTION A-A

from Figure 9

Page 14

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

FIG. 9

31b

31c

31d

31e

31 - Pull Gland Assy

30d

(2)

31a

30e

15e

15a

15b

15c

15d

30c

3536

30b

30a

30 - Piston Assy

15 - Return Gland Assy

(See detail

below.)

Shown without Throttle Guard

26a

26b

29a

29h

29g

29f

29j

29 - Gland Assy

29k

29c 29d

29e

(Note orientation of polyseal)

29b

52a

52b

52c

52b

52 - Seat Assy

25a

25b

SECTION A-A

2122

3342

5253

Page 15

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

Item Description Part No. Qty. 1 Handle & Sleeve Assy 125642 1 2 Cable 125643 1 3 Trigger 124333-2 1 4 Trigger Pin 505496 1 5 Roll Pin 500621 1 6 Wiper Housing 129549 1 7 Stop 110670 1 8 Retaining Nut 117824 1 9 Head Assy contains: 129552 1

Cylinder Head *

n/a 1

9b Seat 111139 1

9c Pin 120203 1

10 Front Gland Assy contains: 129556 1

10a

Front Gland *

n/a 1 10b Polyseal 505865 1 10c O-Ring 500820 1 10d Back-up Ring 501114 1

11 Pull Piston Assy contains: 129555 1

11a

Pull Piston *

n/a 1 11b Back-up Ring 501144 2

11c O-Ring 500850 1

12 Rear Gland Assy contains: 129557 1

12a

Rear Gland *

n/a 1 12b O-Ring 505887 1 12c Back-up Ring 501118 1 12d Polyseal 508428 1

13 Cylinder Cap 129550 1 14 Wiper 505894 1 15 Return Gland Assy contains: 112502 1

15a

Return Gland *

n/a 1 15b O-Ring 500776 1 15c Back-up Ring 501082 1 15d O-Ring 500778 1 15e Back-up Ring 501084 1

16 Throttle Arm Setscrew 502053 1 17 Throttle Valve Assy contains: 115558 1

17a

Throttle Valve *

n/a 1 17b O-Ring 504408 2 17c O-Ring 504407 1 17d Spring 116272 1

18 Button Head Screw 500101 4 19 Self-locking Nut 121241 1 20 Muffler End Cap 120076 1

FIG. 10

* When replacing these parts, the assembly must be

ordered. They are not sold separately.

Parts list continued on next page.

ARTS

IST

(Refer to Figures 9 and 10)

10d

10c

10a

10b

10 - Front Gland Assy

11b

11c

12b

11b

12c

12a

33a

11a

11 - Pull Piston Assy

12d

12 - Rear Gland Assy

33b

33 - Bleed Plug / O-Ring Assy

Page 16

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

Item Description Part No. Qty. 32 Cap Screw 500102 4 33 Bleed Plug / O- Ring Assy contains: 104243 3

33a

Bleed Plug *

n/a 1

33b O-Ring 505438 1

34 Screw 502482 2 35 Screw & Bushing Assy 127029 1 36 Throttle Arm 127688 1 37 Guard 125657 1 38 Air Hose Assy 115436 1 39 Spring 505864 2 40 Housing / Spacer Assy 112403 1 41 Quad Ring 501408 1 42 Reservoir Plunger 112405 1 43 Check Valve Ball 502929 1 44 Check Valve Guide 111067 1 45 Spring 100874 1 46 Screw 120129 1 47 Back-up Ring 501082 2 48 O-Ring 505446 2 49 O-Ring 505438 1 50 Plug 111068 1 51 Plug 120204 1 52 Seat & Seals Assy Assy contains: 114537 1

52a

Seat *

n/a 1

52b Back-up Ring 501082 2

52c O-Ring 505446 1

53 Relief Valve Ball 502506 1 54 Relief Valve Guide 120128 1 55 Sleeve 120127 1 56 Spring 505863 1 57 Relief Valve Plug 114530 1

* When replacing these parts, the assembly must be

ordered. They are not sold separately.

Item Description Part No. Qty. 21 Muffler 115554 1 22 O-Ring 500777 1 23 Gasket 126941-3 1 24 Retaining Ring 505139 1 25 Cylinder Head Assy contains: 113528 1

25a

Cylinder Head *

n/a 1

25b O-Ring 505147 1

26 Piston / Quad Ring Assy contains: 113526 1

26a

Air Piston *

n/a 1

26b Quad Ring 501472 1

27 Piston Rod 113344 1 28 Cylinder Assy 120372 1 29 Gland Assy contains: 127326 1

29a Gland 127324 1 29b Gland Housing 127325 1

29c Back-up Ring 127327 1 29d Back-up Ring 127328 1 29e Polyseal 127329 1

29f O-Ring 500779 1 29g O-Ring 500781 1 29h O-Ring 500784 1

29j O-Ring 500786 1

29k Retaining Ring 502821 1

30 Hydraulic Piston Assy contains: 118866 1

30a

Hydraulic Piston *

n/a 1

30b Screw 117773 1

30c O-Ring 503770 1 30d Back-up Ring 501086 2 30e O-Ring 500773 1

31 Pull Gland Assy contains: 113532 1

31a

Pull Gland *

n/a 1

31b O-Ring 500776 1

31c Back-up Ring 501082 1 31d Back-up Ring 501090 1 31e O-Ring 500784 1

ARTS

IST

(Refer to Figures 9 and 10)

Page 17

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

EASURING

OOL

TROKE

FIG. 11

1. With the Piston in the fully forward position, measure DISTANCE A from face of the Cylinder to the face of the Piston.

2. Cycle tool and keep Piston in the full rearward position by keeping the trigger depressed. Measure

ISTANCE B as above.

3. T

OOL STROKE = DISTANCE B - DISTANCE A

DISTANCE A

DISTANCE B

Page 18

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

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 this 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 forward 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 worn or damaged. c) Throttle valve Cable Assembly is broken.

2 Fastener installation incomplete; No broken pintail.

a) Air pressure too low b) Air Piston Quad‐Ring worn or damaged. c) Reservoir empty or low. See Fill and Bleed section. d) Air in hydraulic system. See Fill and Bleed section. e) Reservoir Springs 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. b) Check for loose Retaining Nut c) Check for piston drift.

4 Tool has piston drift.

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

causing the relief valve to open allowing the piston to drift. Tighten the collet and see Fill and Bleed section.

b) Worn or damaged Return Pressure Relief Valve

in tool, inspect Seat Assembly, O‐ring, Back‐up Rings,

Steel Ball and Valve Spring. Replace if necessary.

c) Worn or damaged Piston Assembly; Inspect O‐rings

and Back‐up Rings (36). Replace if necessary.

5 Hydraulic fluid exhausts with air or leaks at base of

handle.

a) Worn or damaged Gland Assembly; Inspect Polyseal,

O‐rings and Quad‐Ring. Replace if necessary.

6. Hydraulic fluid leaks at rear of Pull Piston

a) Worn or damaged Rear Gland. Inspect Polyseal and

O‐ring, and replace if necessary.

7. Hydraulic fluid leaks at front of Pull Piston.

a) Worn or damaged Front Gland. Inspect Polyseal, O‐

ring, and Back‐up Ring, and replace if necessary.

8. Pull Piston (18) will not return.

a) Throttle Valve stuck; Lubricate O‐rings. b) Throttle Arm, Cable Assembly or Trigger binding.

9. Air leaks at air Cylinder Head (60).

a). Worn or damaged O‐ring. Replace if necessary.

ROUBLESHOOTING

CCESSORIES

Fill and Bleed Bottle ‐ 120337

Seat Removal Tool ‐ 126136

Fill Tool Assy for reservoir ‐ 112465

Stall Nut ‐ 120824

Page 19

256BT Pneudraulic Installation Tool (HK1109) Alcoa Fastening Systems

IMITED

ARRANTIES

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

Outside 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

Americas

Alcoa Fastening Systems

Aerospace Products Tucson Operations

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

Alcoa Fastening Systems

Aerospace Products Carson Operations

PO Box 5268 900 Watson Center Rd. Carson, CA 90749 800‐421‐1459 310‐830‐8200 FAX: 310‐830‐1436

Alcoa Fastening Systems

Industrial Products Waco Operations

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

Alcoa Fastening Systems

Industrial Products Kingston Operations

1 Corporate Drive Kingston, NY 12401 800‐278‐4825 845‐331‐7300 FAX: 845‐334‐7333

Alcoa Fastening Systems

Industrial Products Latin America Operations

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

Far East

Alcoa Fastening Systems

Industrial Products Australia Operations

14 Viewtech Place Rowville, Victoria Australia 3178 03‐764‐5500 Toll Free: 008‐335‐030 FAX: 03‐764‐5510

Europe

Alcoa Fastening Systems

Industrial Products United Kingdom Operations

Unit C, Stafford Park 7 Telford, Shropshire England TF3 3BQ 01952‐290011 FAX: 0952‐290459

Alcoa Fastening Systems

Aerospace Products France Operations

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

A Global Organization

Alcoa Fastening Systems (AFS) maintains company offices throughout the United States and Canada, with subsidiary offices in many other countries. Authorized AFS distributors are also located in many of the world’s

Industrial and Aerospace centers, where they provide a ready source of AFS fasteners, installation tools, tool parts, and application assistance.

For The Long Haul, The Future of Fastening Technology, The Future of Assembly Technology, The Future of Tooling Technology, and Tools of Productivity are service marks of Huck International. Huck provides technical assistance regarding the use and application of Huck fasteners and tooling.

NOTICE: The information contained in this publication is only for general guidance with regard to properties of the products shown

and/or the means for selecting such products, and is not intended to create any warranty, express, implied, or statutory; all warranties are contained only in Huck’s written quotations, acknowledgements, and/or purchase orders. It is recommended that the user secure specific, up‐ to‐date data and information regarding each application and/or use of such products.

HWB898 1003‐5M

1 Corporate Drive, Kingston, NY 12401 • Tel: 800‐431‐3091 • Fax: 845‐334‐7333 • www.alcoafasteningsystems.com

One Great Connection

Alcoa Fastening Systems world-wide locations:

For the Long Haul

™

Certified to

ISO 9001:2008

Industrial Products

Certified to

ISO 14001:2004

Industrial Products