Huck 507 Instruction Manual

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OODDEEL

55007

HYDRAULIC INSTALLATION TOOL

INSTRUCTION MANUAL

12-27-2013

HK480

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507

HYDRAULIC INSTALLATION TOOL

(HK480)

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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).

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OONNTTEENNTTS

EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . .

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retrofit of Earlier Tools . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . .11-12

Assembly Drawing with Part Numbers . . . . . . . . . . . . . . 13

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Notes: are reminders of required procedures.

AAFFEETTY

NNSSTTRRUUCCTTIIOONNS

GLOSSARY OF TERMS AND SYMBOLS:

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

- READ MANUAL prior to using this equipment.

- EYE PROTECTION IS REQUIRED while using this equip-

Bold, Italic type and underlining: emphasizes a specific instruction.

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.

ment.

- HEARING PROTECTION IS REQUIRED while using this equipment.

WARNINGS: Must be understood to avoid severe personal injury.

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

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.

X. HYDRAULIC TOOL SAFETY INSTRUCTIONS:

1. Do not exceed maximum pressure setting stated on tool.

2. Carry out a daily check for damaged or worn hoses or hydraulic connections and replace if necessary.

3. Use only clean oil and filling equipment.

4. Power units require a free flow of air for cooling purposes and should therefore be positioned in a well ventilated area free from hazardous fumes.

5. Ensure that couplings are clan and correctly engaged before operation.

6. Do not inspect or clean the tool while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury.

7. Be sure all hose connections are tight.

8. Wipe all couplers clean before connecting. Failure to do so can result in damage to the quick couplers and cause overheating.

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EESSCCRRIIPPTTIIOON

PPEECCIIFFIICCAATTIIOONNS

Huck Model 507 Inline Hydraulic installation Tool is designed to install C50L HUCKBOLT® Fasteners and HLC50L HUCKLOK® Fasteners and to operate on PULL pressure of

5400‐5700 psi (372‐393 BAR) and RETURN pressure of 2200‐2400 psi (152‐165 BAR) as supplied by Huck Hydraulic

Powerig® Models 940, 918, or equivalent.

The Model 507, when equipped with the proper Nose Assembly, which must be purchased separately, is used to install ‐32 (1” diameter) or ‐36 (1‐1/8 diameter) fasteners.

Each tool has a cylinder and piston assembly. An relief valve, designed to relieve the hydraulic pressure at both

POWER SOURCE:

Huck POWERIG Hydraulic Unit

HOSE KITS:

Use only genuine HUCK Hose Kits rated @ 10,000 psi working pressure.

MAX OPERATING TEMP:

125°F (51.7°C)

MAX FLOW RATE:

2 gpm (7.5 l/m)

MAX PULL PRESSURE:

5700 psi (393 bar)

MAX RETURN PRESSURE:

2400 psi (165 bar)

PULL CAPACITY:

75,700 lbs (337 kN)

STROKE:

2.5 inches (6.35 cm)

WEIGHT:

43 lbs (19.5 kg)

ends of the stroke, is positioned by the piston. A pintail ejector is provided to eject the broken pintail from the nose assembly. The end of the piston rod is threaded and a nose adapter and retaining rings are included for attaching nose assemblies.

Lengths and weights do not include Nose Assemblies.

Correct PULL and RETURN pressures are important for the proper function of the Tool and Nose Assemblies, and for the safety of the operator. HUCK Gage T‐124833CE is avail‐ able for checking these pressures. Instructions are furnished with the gage and Powerig® Instruction Manuals.

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."

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WARNING: Huck recommends that only Huck Powerig Hydraulic Units be used as a power source for Huck installation equipment. Hydraulic power units that deliver high pressure for both PULL and RETURN, AND ARE NOT EQUIPPED WITH RELIEF VALVES ARE SPECIFICALLY NOT RECOMMENDED AND MAY BE DANGEROUS.

When tool hoses and cord are connected to Powerig hoses and control cord, PULL and RETURN strokes of tool are con‐ trolled by a Trigger in the handle.

When the trigger is depressed, a solenoid operated valve in the POWERIG directs pressured fluid through the FILL Hydraulic Hose to the front side of piston, and allows fluid on the RETURN side to flow back to tank.

The piston and nose assembly collet moves rearward caus‐ ing follower O‐rings and/or spring to impart a forward motion to the follower.

If tool and nose assembly is in position on a fastener pin and collar, this forward motion causes the jaws to clamp onto pintail of fastener and installation cycle commences.

OOFF

When the anvil hits the sheet, continued pull causes the pintail to break off. When the Piston reaches the end of its PULL stroke, it uncovers flats on the rear end of the Relief Valve. These flats were designed to provide a passage for hydraulic fluid from PULL side to RETURN side of piston, “unloading” or “dumping” the pressurized fluid back to tank. When the trigger is released, the solenoid is de‐energized and the valve directs pressurized fluid to rear side of the piston and allows fluid on PULL side to flow back to tank.

This causes piston and collet to move forward and pushes nose assembly and tool off the swaged (installed) fastener. Nose assembly jaw release contacts jaws, causing them to open and release the broken‐off pintail. The Ejector Rod hydraulically ejects the pintail out the front of the nose assembly. When the piston reaches the end of its RETURN stroke, pressure is built up causing the Powerig idler valve (except on Models 910 and 911) to go to idling pressure. Idling pressure keeps the tool piston and nose assembly collet, jaws, etc. in the forward position ready for the next installation cycle.

A flat on the front end of the relief valve was designed to provide a passage for hydraulic fluid from RETURN side of piston to PULL side of piston and back to tank.

Clamping pressure is applied to the sheets. The anvil is forced forward, swaging the collar into locking grooves of the fastener.

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SSE

FFOORR

Read all WARNINGS and CAUTIONS before operating HUCK Installation Tools.

WARNINGS: Read full manual before using tool.

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

When operating Huck installation equipment, always wear approved eye protection.

Be sure there is adequate clearance for the operator’s hands before proceeding.

Connect Tool’s hydraulic hoses to Powerig Hydraulic Unit before connecting Tool’s switch control cord to unit. If not connected in this order, severe personal Injury may occur.

Correct PULL and RETURN pressures are required for operator’s safety and for Installation TooI’s function. Gauge Set-Up T-124883CE is available for checking pressures. See Tool SPECIFICATIONS and Gauge Instruction Manual. Failure to verify pressures may result in severe personal injury.

CAUTIONS: Do not let disconnected hoses and couplers contact a dirty floor. Keep harmful material out of hydraulic fluid. Dirt in hydraulic fluid causes valve failure In Tool and In POWERIG Hydraulic Unit.

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

POWER SOURCE CONNECTIONS

Coat hose fitting threads with a non-hardening Teflon thread compound such as Slic-tite. (Slic-tite is available from Huck as part number

503237.)

1. Screw PULL pressure hose, part number 104490, with coupler nipple, part number 103391, into tool port “P.” Screw RETURN pressure hose, part num- ber 104490, with coupler body, part number 103392, into tool port ‘‘R.’’

2. Use a Huck Powerig or equivalent that has been prepared for operation per applicable instruction manual. Check both PULL and RETURN pressures and adjust as necessary. Gage part number T- 124833CE, for checking POWERIG pressures, is available from Huck.

3. Turn Powerig to “OFF” and couple tool hoses to Powerig hoses. Be sure that the larger hoses run from tool port “P” to POWERIG port “P” and the smaller hoses run from tool port “R” to POWERIG port “R”.

4. Connect trigger cord to POWERIG cord.

5. Turn POWERIG to “ON” and depress and release trigger a few times to circulate hydraulic fluid. Observe action of tool. Check for fluid leaks.

6. Attach the proper Nose Assembly to the tool.

Hose couplers must be completely screwed together to insure that ball checks in both nipple and body are completely open. Improperly assembled couplers will cause overheating and malfunctions in both tool and Powerig. Hand tighten couplers. Do NOT use a pipe wrench.

NOTE: Model 507 H.I.T. with a serial number 0847 and above has a deeper pocket in the end of the piston rod. This allows clearance for the pintail. A longer jaw follower CAP, P/N 122686 is required in the nose assembly. CAP, P/N 104411 is required with previous tools.

* Slic-Tite is a registered trademark of LA-CO Industries, Inc. * TEFLON is a registered trademark of DuPont Corp.

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PPEERRAATTIINNG

NNSSTTRRUUCCTTIIOONNS

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.

For safe operation. Please read completely

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.

Operators should receive training from qualified personnel.

Do not bend tool to free if stuck. Only use tool to install fasteners. NEVER

use as a jack/spreader or hammer.

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.

TO INSTALL A HUCKBOLT FASTENER:

1. Check work and remove excessive gap. (Gap is the

space between sheets. Gap is excessive if not enough pintail sticks through the collar for the nose assembly jaws to grab onto).

2. Put HUCKBOLT® pin in hole.

3. Slide HUCKBOLT® collar over pin. (The beveled

end of the collar must be towards the nose assembly and tool.)

4. Push nose assembly onto the pin until the nose

assembly anvil stops against the collar. Tool and nose assembly must be held at right angles (90 degrees) to the work.

5. Depress tool trigger to start installation cycle.

6. When forward motion of nose assembly anvil stops

and pintail breaks off, release trigger. Tool will go into its return stroke, push off the installed fastener and eject the pintail.

7. The tool and nose assembly is ready for the next

installation cycle.

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IITTS

CCCCEESSSSOORRIIEES

Service Kit

Includes Seals, etc for tool service.

507KIT

Hex Key, 5/16 across flats

Socket Head Screws in Handle

502446

Hex Key 3/32 across flats

Set Screw in Trigger Switch

501623

Locking Ring Wrench

Locking Ring

110362

Clamp and Bracket Kit (shown below)

Tool Hose Support

130029

YYDDRRAAUULLIIC

OOUUPPLLIINNGGS

AANNDD

DESCRIPTION USED FOR PART NO.

130029 Clamp and Bracket Kit

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At regular intervals, depending on use, replace all O-

AAIINNTTEENNAANNCCE

PPEECCIIFFIICCAATTIIOONNS

RROOUUBBLLEESSHHOOOOTTIINNG

IISSAASSSSEEMMBBLLY

AANND

SSSSEEMMBBLLY

EETTRROOFFIIT

LLDDEER

OOOOLLS

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.

- Always check tool assembly drawing for the proper direction of the flats on the Dump Valve.

4. Inspect tool, hose, and POWERIG during operation to detect abnormal heating, leaks, or vibration.

POWERIG Maintenance

Maintenance instructions and repair procedures are in the appropriate POWERIG Instruction Manual.

Tool Maintenance

See SS in accordance with local environmental regulations.

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

PREVENTIVE MAINTENANCE NOTE: For supplementary information refer to

procedures in this manual.

for fluid type. Dispose of fluid

, Parts Lists, and DD

System Inspection

Operating efficiency of the installation tool is directly related to performance of the complete system, including the tool with nose assembly, hydraulic hoses, trigger and control cord, and POWERIG. Therefore, an effective preventive maintenance program includes scheduled inspections of the system to detect and correct minor troubles.

rings and back-up rings in the tool. Spare Parts Kit 507KIT should be kept on hand. Inspect cylinder bore, piston and piston rod and unloading valve for scored surfaces, excessive wear or damage, and replace as necessary.

Nose Assembly Maintenance

Daily cleaning of the nose assembly is recommended. This can usually he accomplished by dipping nose assembly in mineral spirits, or other suitable solvent, to clean jaws and wash away metal chips and dirt. If more thorough cleaning or maintenance is necessary, disassemble the nose assembly. Use a sharp pointed “pick” to remove imbedded particles from the pull grooves of the jaws. Reassemble per instructions on the applicable Nose Assembly Data Sheet.

1. Inspect tool and nose for external damage.

2. Verify that hydraulic hose fittings and couplings and electrical connections are secure.

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

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 part

number 503237.)

3. Inspect hydraulic hose for signs of damage or aging. Replace hose at six-month to one-year intervals, depending on use.

Replacement parts are available for earlier model tools. If replacement parts are needed for serial num- ber below 0847, it is strongly recommended that the tool be updated to the most current configuration. Please call your Technical Support representative for the correct part numbers.

OOFF

Optional Accessory

Suspension Bracket is available. When used with a balance spring suspension system, much of the tool’s weight is supported. Operator fatigue is alleviated for longer periods. Please contact Customer Service for Part Number and Availability.

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EENNEERRAAL

IISSAASSSSEEMMBBLLY

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UUIIDDEELLIINNEES

IISSAASSSSEEMMBBLLY

NNSSTTRRUUCCTTIIOONNS

For component identification, refer to Figure 1.

The following procedure is for disassembly of Tool.

Remove one Locator Button and unscrew Locking Ring using spanner wrench. Remove the second

Remove only those parts necessary. Check and

Locator Button.

replace damaged/worn components. Always replace

O-rings, wipers, and back-up rings of disassem-

4. Screw Locking Ring part way in. Screw two Socket

bled subassemblies.

Head Screws into Cylinder Cap. Use pry bars under the heads of the screws to gradually pry

NOTE: Be sure POWERIG is turned “OFF” when removing the nose assembly to clean or replace

Cylinder Cap out of Cylinder Assembly. Remove Rnloading Valve.

components. See applicable Nose Assembly Data Sheet for additional instructions.

6. Drain hydraulic fluid from Cylinder Assembly.

During disassembly and assembly, take the following precautions to avoid damaging tool or components: (a) Always work on a clean surface.

(b) Use relatively soft materials, such as brass, alu-

minum or wood, to protect tool when applying pressure.

sharp blows, to disassemble or assemble a component. An arbor press provides steady pressure to press a component in or out.

(d) Never continue to force a component if it

“hangs.up” due to misalignment. Reverse the procedure to correct misalignment and start over.

(e) Smear Lubriplate 130AA

T.M

or equivalent, on O-

AANNDD

rings and mating surfaces to aid assembly and prevent damage to O-rings.

(Lubriplate is a registered trademark of Fiske Brothers Refining Co. A handy tube of Lubriplate 130AA is available from Huck as part number 502723).

A special Spanner Wrench, Part No. 110362, is available from Huck to aid in the disassembly and assembly of Locking Ring, reference No. 11. Piston Rod Guide Part No. 102862 are available to prevent damage to piston rod seals when assembling the piston.

Standard hand tools such as wrenches, drifts, copper or lead hammers, screwdrivers, socket screw hexagon keys, long forceps (tweezers), etc. Which can be purchased at most local supply firms are required. If possible, an arbor press and vise with soft jaws should be available.

WARNING: Be sure to disconnect Tool’s electrical control trigger system from POWERIG® Hydraulic Unit BEFORE disconnecting Tool’s hydraulic hoses from unit. If not disconnected in this order before any maintenance or cleaning is

1. Remove Retaining Ring from Split Ring, slide off

done, severe personal injury may occur.

Sleeve and remove Split Ring segments. Pull nose assembly anvil off and unscrew nose collet assembly.

2. Remove four Socket Head Screws and Lockwashers from Handle. Handle Assembly and Cushion are now separated from the Tool.

7. Unscrew Hoses.

8. Press Piston out of CylinderAssembly. Use an arbor press if one is available.

9. Unscrew Ejector Cartridge Assembly using 7/16 socket wrench. Slide Ejector out of cartridge assembly. Unscrew Retaining Screw from cartridge assembly using 3/16 allen wrench.

10. Remove Retaining Ring.

11. Press Adapter out of Cylinder Assembly.

12. Use a small dull-pointed rod to remove O-Rings and Back-up Rings from all components.

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For component identification, refer to Figure 1.

Before assembling tool:

(a) Clean components In mineral spirits or other

solvent compatible With O-ring seals. (b) Clean out O-Ring grooves. (c) Inspect components for scoring, excessive wear or

damage. (d) Replace O-Rings and back-up rings. Be sure that

relative positions of the O-Rings and back-up rings

are as shown in Figures. (e) Specifications for O-Rings, back-up rings and

other standard components are shown in Table 5

so that they may be purchased locally. (f) Smear Lubriplate 130AA on O-Rings and mating

surfaces to prevent damage to O-Rings and to aid

assembly.

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

1. Press nose assembly adapter into Cylinder.

2. Place O-Ring and Washer into Ejector Cartridge.

Install Retaining Screw using 3/16 allen wrench. Push pintail Ejector into Ejector Cartridge. Install O-Ring and Back-up Ring on outside of Cartridge. Screw Cartridge Assembly into Piston. Tighten with 7/16 socket wrench. Note: Step 4 may be

done before assembling pintail Ejector and Ejector Cartridge to Piston.

3. Place Piston Rod Guide P/N 102862 over the

threads of Piston rod and press Piston into Cylinder and Adapter.

4. Place Relief Valve in hole in Piston.

5. Press Cylinder Cap into Cylinder so that the loca-

tor scallop in the cap matches the scallop in the cylinder.

6. Place one Locator in matching scallops. (Cap can

be turned by putting a screw into one of the tapped holes to use as a handle).

7. Screw Locking Ring into Cylinder using spanner

wrench.

8. Unscrew Locking Ring 1/4 turn or less until scallop

in Locking Ring matches scallop in Cylinder Cap. Place Locator in matching scallops.

9. Position Cushion and Handle assembly in place and assemble four Socket Head Screws and Lockwashers. Tighten Screws to 490 inch pounds torque if screws are plated and 655 inch pounds if screws are unplated.

10. Screw Hoses into Cylinder. Coat hose fitting threads with a non-hardening TEFLONTM.

CAUTION: Do not use TEFLON® tape on pipe threads. Pipe threads may cause tape to shred resulting in tool malfunction. (Slic-

Tite number 503237.)

11. Screw coupler Nipple onto Hose assembled into cylinder PORT “P.”

12. Screw coupler Body onto Hose assembled into cylinder PORT “R.” (Note: Tool will malfunction if coupler Nipple and Body are not properly assembled.)

13. Attach tool hoses to Powerig hoses and

actuate tool a few times to check operation of tool and inspect for leaks caused by damaged O-Rings.

14. Assemble Split Ring, Sleeve and Retaining Ring

when attaching the nose assembly.

Handle Assembly

1. Screw body of cord grip part of Strain Relief into

Handle.

2. Slide Strain Relief cap over cord.

3. Slide Strain Relief grommet over cord.

4. Place Cord in Handle so that leads come out the

Switch pocket.

5. Assemble leads to rear of Switch.

6. Push Switch into Handle and retain

with Set Screw.

7. Slide cover (not shown) over other end of Cord.

8. Assemble cap (two-prong plug) to Cord,

and slide cover over cap.

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

is available in stick form as Huck part

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HYDRAULIC INSTALLATION TOOL

(HK480)

Arconic

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507

HYDRAULIC INSTALLATION TOOL

(HK480)

Arconic

RROOUUBBLLEESSHHOOOOTTIINNG

Always check the simplest possible cause of a malfunction first. For example, a loose or disconnected trigger line. Then proceed logically, eliminating each possible cause until the defective part is located. Where possible, substitute known good parts for suspected defective parts. Use Trouble Shooting Chart as an aid for locating and correcting trouble.

1. Tool fails to operate when trigger is depressed.

a. Inoperative POWERIG® Hydraulic Unit. Check

power source and/or see applicable Powerig

instruction manual. b. Loose or disconnected control cord. c. Damaged trigger assembly. d. Loose or faulty hydraulic hose couplings.

2. Tool leaks hydraulic fluid.

a. Defective Tool O-rings or loose hose connections

at Tool.

3. Hydraulic couplers leak fluid.

a. Damaged or worn O-rings in coupler body.

4. Hydraulic fluid overheats.

a. Powerig not operating properIy. b. Hydraulic couplers not completely tightened. d. Restriction in hydraulic line.

10. Pull grooves on fastener pintail stripped during PULL stroke.

a. Broken pintail not removed from tool. b. Anvil was not slid completely onto fastener pintail. c. Incorrect fastener length. d. Worn or damaged jaw segments. e. Metal particles accumulated in pull grooves of

jaw segments.

f. Excessive sheet gap.

11. Tool operates in reverse.

a. Reversed hydraulic hose connections between

POWERIG and tool.

12. Anvil will not slide completely over fastener pintail.

a. Broken pintail not removed from tool. b. Incorrect fastener length.

5. Tool operates erratically and fails to install fastener

properly.

a. Low or erratic hydraulic pressure; air in system b. Damaged or worn piston/anvil O-ring in Tool. c. Excessive wear on sliding surfaces of Tool parts. d. Relief Valve too short, worn, or peened over.

6. Collar of HUCKBOLT® fastener not completely

swaged.

a. Improper Tool operation. See Trouble 5. b. Scored anvil.

7. Tool “hangs-up” on swaged collar of HUCKBOLT

Fastener.

a. Improper Tool operation. See Trouble 5. b. RETURN pressure too low.

8. Pintail of fastener fails to break.

a. Improper Tool operation. See Trouble 5. b. Pull grooves on fastener stripped. See Trouble 10. c. PULL pressure too low.

9. Jaw segments do not maintain proper position in

piston.

a. Incorrect amount of follower O-rings. Clean before

reassembling.

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HYDRAULIC INSTALLATION TOOL

(HK480)

Arconic

LIMITED WARRANTIES

Limited Lifetime Warranty on BobTail® Tools:

Huck International, Inc. warrants to the original purchaser that its BobTail® installation tools manufactured after 12/1/2016 shall be free from defects in materials and workmanship for its useful lifetime. This warranty does not cover special order / non-standard products, or part failure due to normal wear, tool abuse or misapplication, or user non-compliance with the service requirements and conditions detailed in the product literature.

Two Year Limited Warranty on Installation Tools:

Huck International, Inc. warrants that its installation tools manufactured after 12/1/2016 shall be free from defects in materials and workmanship for a period of two years from date of purchase by the end user. This warranty does not cover special order / non-standard products, or part failure due to normal wear, tool abuse or misapplication, or user non-compliance with the service requirements and conditions detailed in the product literature.

90 Day Limited Warranty on Nose Assemblies and Accessories:

Huck International, Inc. warrants that its nose assemblies and accessories shall be free from defects in materials and workmanship for a period of 90 days from date of purchase by the end user. This warranty does not cover special clearance noses, or special order / non-standard product, or part failure due to normal wear, abuse or misapplication, or user non-compliance with the service requirements and conditions detailed in the product literature.

Useful lifetime is defined as the period over which the product is expected to last physically, up to the point when replacement is required due to either normal in-service wear, or as part of a complete overhaul. Determination is made on a case-by case basis upon return of parts to Huck International, Inc. for evaluation.

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.

Huck shall not be liable for any loss or damage resulting from delays or non-fulfillment 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 location (see reverse).

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 Tool Kits and Nose Assemblies. Please contact your Huck Representative or the nearest Huck International location (see reverse) for the ATSC in your area.

Page 16

For the Long Haul

™