Huck Model 246 - Blind Rivet Supply

INSTRUCTION MANUAL
246
PNEUDRAULIC INSTALLATION TOOL
HUCK
246
11-23-2010
HK825
Model 246 Tool
Alcoa Fastening Systems
EU Declaration of Conformity
Manufacturer:
Alcoa Fastening Systems, Commercial Products Division, 1 Corporate Drive, Kingston, NY,
12401, USA
Description of Machinery:
Model numbers 246 and 256 fastener installation tools
Relevant provisions complied with:
Council Directive related to Machinery, (89/392/EEC), (91/368/EEC), (93/44/EEC),
(93/68/EEC)
Council Directive related to EMC/EMI, (89/336/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, 2005
Sound Levels
Vibration Levels
Models: 246 and 256
Models: 246 and 256
SEL
dB (A)
Peak Value
dB (C)
Leq
dB (A)
90.6
117.5
77.9
Leq reflects the
equivalent noise
level result of
installing 1,500
typical Huck
fasteners for an
eight hour work
day.
To calculate equivalent noise level for other quantities of
fasteners in an eight hour period, use the formula:
Leq = SEL + 10 log (n/28,800)
where n = number of fasteners in eight hours.
For an eight hour work day, installing 1,500 typical Huck
fasteners will result in an equivalent weighted RMS
vibration level A(8) of:
2.5 m/s2
To calculate equivalent vibration level for other quantities of
fasteners in an eight hour period, use the formula:
Equivalent Vibration Level, A8 (m/s2) = (n/480) x 0.8
where n = number of fasteners in eight hours,
and
0.8(m/s2) = Aeq for 60 seconds.
Test data to support the above information is on file at Alcoa Fastening Systems, Commercial Products Division, Kingston
Operations, Kingston, NY, USA. Vibration measurements are frequency weighted in accordance with ISO 8041 (1990).
2
Model 246 Tool
Alcoa Fastening Systems
CONTENTS
EU DECLARATION
OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRINCIPLE
OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PREPARATION
SERVICING
FOR
USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
THE TOOL
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
Fill and Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3
Model 246 Tool
Alcoa Fastening Systems
S AFETY
10. Make sure proper power source is used at all times.
This instruction manual must be read, with particular
attention to the following safety guidelines, by any
person servicing or operating this tool.
11. Release tool trigger if power supply is interrupted.
1. Glossary
!
12. Tools are not to be used in an explosive environment
unless specifically designed to do so.
Product complies with requirements set forth
by the relevant European directives.
13. Never remove any safety guards or pintail deflectors.
Read manual prior to using this equipment.
14. Where applicable, ensure deflector or pintail collector is
installed and operating prior to use.
Eye protection is required while using this
equipment.
15. Never install a fastener in free air. Personal injury from
fastener ejecting may occur.
Hearing protection is required while using
this equipment.
16. Where applicable, always clear spent pintail out of nose
assembly before installing the next fastener.
17. There is possibility of forcible ejection of pintails or
spent mandrels from front of tool.
WARNINGS: Must be understood to avoid
severe personal injury.
18. If there is a pinch point between trigger and work piece,
use remote trigger. (Remote triggers are available for
all tooling).
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.
19. Unsuitable postures may not allow counteracting of
normal expected movement of tool.
20. 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 in preventing an
accident which may cause severe personal injury.
2. A half hour long hands-on training session with qualified
personnel is recommended before using Huck
equipment.
3. 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.
21. Never place hands between nose assembly and work
piece. Keep hands clear from front of tool.
22. There is a risk of crushing if tool is cycled without Nose
Assembly installed.
4. Repairman and Operator must read manual prior to
using equipment. Warning and Caution stickers/labels
supplied with equipment must be understood before
connecting equipment to any primary power supply. As
applicable, each of the sections in this manual have
specific safety and other information.
23. Tools with ejector rods should never be cycled with out
nose assembly installed.
24. When two piece lock bolts are being used always make
sure the collar orientation is correct. See fastener data
sheet of correct positioning.
5. Read MSDS Specifications before servicing the tool.
MSDS Specifications are available from the product
manufacturer or your Huck representative.
6.
25. Tool is only to be used as stated in this manual. Any
other use is prohibited.
When repairing or operating Huck installation
equipment, always wear approved eye protection.
Where applicable, refer to ANSI Z87.1 - 2003
26. There is a risk of whipping compressed air hose if tool
is pneudraulic or pneumatic.
7. Disconnect primary power source before performing
maintenance on Huck equipment or changing Nose
Assembly.
27. Release the trigger in case of failure of air supply or
hydraulic supply.
28. Use only fluids or lubricants recommended.
8. Tools and hoses should be inspected for leaks at the
beginning of each shift/day. If any equipment shows
signs of damage, wear, or leakage, do not connect it to
the primary power supply.
29. Disposal instruction: Disassemble and recycle steel,
aluminum and plastic parts, and drain and dispose of
hydraulic fluid in accordance with local lawful and safe
practices.
9. Mounting hardware should be checked at the beginning
of each shift/day.
30. If tool is fixed to a suspension device, ensure that the
device is secure prior to operating the tool.
3
Model 246 Tool
Alcoa Fastening Systems
TOOL SPECIFICATIONS
INCHES
8.810
223.75
MM
.732
18.60
4°
HUCK
246
ø
1.920
48.80
15.050
382.30
6.155
156.30
6.125
ø
155.60
• Stroke: .875
• Weight: 11.1 lbs
3.980
101.10
• Air Pressure: 90-100 psi
• Capacity: 9986 lbs @ 90 psi
• Speed/Cycles: 30 per minute
• Noise Level: 85 dBA @ 90 psi
5
Model 246 Tool
Alcoa Fastening Systems
PRINCIPLE OF OPERATION
PULL PISTON
RELIEF
VALVE
CHECK
VALVE
HYDRAULIC
PISTON
THROTTLE
VALVE
RESERVOIR
EXHAUST
AIR PISTON
PULL
RETURN
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 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.
6
Model 246 Tool
Alcoa Fastening Systems
PREPARATION FOR USE
The Model 246 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 20
CFM must be available. Air supply should be equipped with
a filter-regulator-lubricator unit.
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.
(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).
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 503237)
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.
NOTES:
1 Air quick disconnect fittings and air hoses are not
available from Huck International, Inc.
2 VIBRA-TITE, Huck part number 505125, should be
used on collect threads for nose assemblies without
lock collars. All other noses should be stake (please
refer to nose assembly data sheets).
SERVICING THE TOOL
GENERAL
DAILY
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 246KIT includes consumable parts
and should be available at all times. Other components,
as experience dictates, should also be available.
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.
!
WEEKLY
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.
WARNING: Inspect tool for damage or wear
before each use. Do not operate if damaged or
worn, as severe personal injury may occur
7
Model 246 Tool
Alcoa Fastening Systems
MODEL 246 DISASSEMBLY INSTRUCTIONS
!
9. 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).
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.
For component identification and Parts list refer to
Figure ( 9 ).
Disassembly
10. Unscrew Plug (71) of reservoir check Valve from side
of head. Remove Spring (75), check Valve Plunger
(76) and Stainless Steel Ball (77) (Fig.1).
(Refer to Figures 1-3 and 9)
11. 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).
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.
12. (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), 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).
1. Disconnect air hose from tool.
2. Remove air hose (38) from cylinder.
4. Remove nose assembly. Follow instructions on Nose
Assembly Data sheet.
13. Pintail Deflector (19) can be pulled off deflector tube at
rear of Piston.
3. Remove Screws (63) and Guard
(68) (Fig. 9).
5. Insert Fill Tool, P/N 112465
through reservoir housing and
screw into reservoir plunger (79)
locking it in the out position
(Fig.1).
6. Unscrew cap screws (69) with
5/32 hex key. Carefully lift Head
straight up from Handle (1),
remove Pull Gland (95) and
Return
Gland
(22)
from
separated assemblies.(Remove
seals from glands) (Fig.1).
7. 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).
8. Unscrew Bleed Plug (64). Hold
over waste oil container and
release fill tool slowly.
FIG. 1
Lock-out Position
FILL TOOL
112465
HUCK
SPACER
64
81
80
82 (2)
19
20
79
89
86 84
70
74
71 75 76 77
22
1
69 (4)
8
85
95
87
83
Model 246 Tool
Alcoa Fastening Systems
14. Unscrew End Cap (20) from Head (89) with 1 9/16
open end wrench (Fig.9).
FIG. 3
45
15. Thread assembly/disassembly bullet (120792) onto
piston. Tap or press piston assembly out of head.
Remove wiper (9) and polyseal (10).
NOTE: Piston will push out rear gland assembly. (Fig. 2)
42
46
43
16. Remove Screw (67) from Throttle Arm (66). Remove
throttle arm. Pull Throttle Valve (36) out of cylinder.
Remove Spring (40). (Fig. 9).
44
47
49
48
17. With a small punch and hammer, drive Roll Pin (5)
from handle (1). Remove trigger and cable from
handle and disassemble by removing pin (4) (Fig. 9).
51
50
52
18. Remove Bleed Screw (64) from handle (Fig. 3).
19. Hold tool inverted in vice. Unscrew three Button Head
Screws (45) with 1/8 hex key. (Fig 3).
53
20. Remove bottom Plate (42), Bottom Exhaust Gasket
(46), Muffler (43) and O-ring (44) (Fig 3).
21. Remove Retaining Ring (47) from Cylinder (53)
(Fig 3).
54
22. Screw button head screws (45) into Cylinder Head
(49). Carefully pry under screws to remove cylinder
head.
23. Push air piston all the way down in cylinder, lay tool on
its side. Hold nut (41) with a 9/16 socket and
extension and with 7/64 hex key, remove piston screw
(32) (Fig 4 & 9).
1
24. Turn cylinder and handle upside down and secure in a
vise.
25. Grip lock nut (41) under Air Piston with pliers and pull
piston and rod assembly from handle and cylinder
assembly (Fig 3).
CAUTION: Care must be taken not to scratch piston
rod or cylinder during removal.
9
26. With a 1 3/8 socket and extension, remove Gland
Assembly (54). Handle and cylinder will now separate.
27. 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.
FIG. 2
10
28. Remove and replace seals from Gland Assembly (54),
if necessary. (Fig. 9)
Assembly Bullet
120792
HUCK
246
9
Model 246 Tool
Alcoa Fastening Systems
MODEL 246 ASSEMBLY INSTRUCTIONS
Assembly
Hydraulic Piston (34) and screw into top of piston
rod. Hold Nut (41) with 9/16 socket and extension
and torque Screw (32) using 7/64 hex key to 55 - 60
in. lbs.
(Refer to Figures 2, 3, 4, 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 246KIT 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.
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). (Fig. 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 Bottom Plate
(42). Place Bottom Plate (42) on top of Gasket and
secure with 3 Button Head Screws (45) using 1/8
hex key. (Fig. 3)
1. Holding handle inverted in a vice, Place Cylinder
(53) on handle with Timing Pin positioned in
matching hole. Assemble Gland Assembly (54) (See
Fig. 9). Screw complete Gland assembly into
handle. Torque to 100 - 120 ft. lbs. using 1 3/8
socket wrench.
7. Turn tool upright. Drop spring (40) into Throttle valve
hole in cylinder. Push Throttle Valve (36) with Orings (37 & 39) in place into cylinder. (Fig. 9)
8. Assemble Trigger (3) cable (2) and 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)
2. Push Air Piston/Rod assembly with Quad ring (50) in
place into Air Cylinder until it bottoms at top of
Cylinder (Fig 4).
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.
FIG. 4
31 Piston
Assembly
10. Attach hose (38).
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. Install Wiper (9) & Variseal (10) in head. (Fig. 2 & 9)
41
15. Thread assembly bullet onto Pull Piston (11), and
push entire assembly into head. (Fig. 2)
16. Install O-rings (14 & 16) & Back-up Rings (15 & 17)
on rear gland (18). Push complete assembly into
head, screw in End Cap (20) and tighten. (Fig. 9)
3. Turn tool upright. Install Hydraulic Piston (31) (with
O-ring (33) and Back-up rings (99) 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
10
Model 246 Tool
Alcoa Fastening Systems
MODEL 246 ASSEMBLY INSTRUCTIONS
(CONTINUED)
17. Install O-ring (72) & Back-up Ring (25) on Plug (83).
Install Ball (87), Guide (86), Sleeve (85), Spring (84)
and Plug (83) into head. (Fig. 1 & 9).
FIG. 5
18. Install O-ring (65) on Plug (71). Install Ball (77),
Guide (76), Spring (75) and Plug (71) into head.
89
22
19. Push Deflector (19) onto Deflector Tube (21). (Fig. 9)
20. Place O-ring (65) on Plug (64) and screw assembly
into Handle (1). (Fig. 9)
1
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 into handle. Push head down on glands.
Place tool in a vise Head down and install 4 Screws
(69) and torque to 170 inch pounds. (Fig. 5)
95
69
(4)
22. Tool is now completely assembled and ready for Fill
& Bleed.
SERVICE NOTES
11
Model 246 Tool
Alcoa Fastening Systems
FILL AND BLEED MODEL 246
Equipment Required:
- Shop airline with 90 - 100 psi max.
- Air regulator
- Fill bottle, 120337, (supplied with tool).
- Fill Tool, 112465, (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)
Step 4
Attach 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. (See Fig. 7)
120824
Stallnut
HUCK
FIG. 6
Fill Tool
112465
Lock-out
Fill Point
Red Line
Indicator
64
120337
Fill Bottle
Assembly
84 83
71
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.
!
FIG. 7
8
75 76 77
85 87
86
Install Fill & Bleed
Bottle here
(”Check Valve Hole”)
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.
Step 5
Install fill bottle in head fill port (check Valve hole) (See
Fig. 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. Note: When cycling tool, always hold bottle
up as shown in Figure 8 to prevent drawing in air
from empty part of bottle.
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).
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.
Step 3
Screw retaining nut onto head assembly. Screw stall nut
(optional) 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 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)
12
Model 246 Tool
Alcoa Fastening Systems
FILL AND BLEED MODEL 246
(CONTINUED)
Step 9
Turn tool so front of head faces you and remove the relief
valve plug (83). Prior to removing Plug (83), it is
advisable to back out setscrew inside of plug by
approximately 1/2 turn counterclockwise. (See Figure
7a). This ensures that the Piston will remain in fullforward position. and install relief valve ball (87), guide
(86), sleeve (85) and spring (84). Replace the plug (83)
and re-tighten setscrew.
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.
FIG. 8
FIG. 7a
83
Using a 3/32 Allen
wrench, loosen
setscrew inside Plug by
approx. 1/2 turn.
SECTION A-A
from figure 9
Step 10
Unlock Fill Tool and check Reservoir red line. At this
point cycle tool with Stall Nut (Optional see note:)
attached 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 13
Remove fill tool and stall nut (if used). Install a nose
assembly and pull several fasteners to test function.
Step 11
Re-lock the fill tool in out position. Lay tool on its left side
and remove plug (64). Top off reservoir - - place 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).
!
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.
13
Model 246 Tool
Alcoa Fastening Systems
ASSEMBLY DRAWING
FIG. 9
34
35
8 11 9 10 97 12 13 14 15 16 17 18
89
96 19
99
33
A
A
32
7
(31) PISTON
ASSEMBLY
69
23
27
20
5
69
21
4
24
22
3
25
26
67
68
66
95
2
65
(22) RETURN
GLAND ASSEMBLY
31
1
64
100
54
63
24
25
6
36
53
28
37
29
52
30
(95) PULL
GLAND ASSEMBLY
51
B
50
49
48
B
39
40
47
46
60
82
59
57
45
44
80
81
42
43
79
72
45
41
64
65
30
58
78
77
76
75
94
61
56
55
62
74
(54) GLAND ASSEMBLY
83
M PRESS 110
A
X FLOW 30
SCFM
92
PSI
850
7.6
L/M
HUCK MODEL
SER. NO.
BAR
GPM
93
246
MADE IN USA
90
HUCK INTL,INC
1 CORP. DRIVE
KINGSTON, N.Y.
12401 USA
91
14
25
72
84
85
86
87
88
25 64 65
SECTION A-A
70
73
72 25
71 65
Model 246 Tool
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
PART#
125642
125643
124333-2
505496
500621
108279
110670
117824
505894
505865
120331
113251
500851
505791
113754
505887
113253
120056
124209
112491
120325
112502
112427
500776
501082
500778
501084
113341
501090
500784
118866
117773
503770
117775
500773
127888
504408
115436
504407
116272
121241
120076
115554
500777
500101
125724-3
505139
505147
113345
501472
113320
DESCRIPTION
Handle & Sleeve Assembly
Cable Assembly
Trigger
Pin
Pin
Pintail Tube
Stop
Retaining Nut
Wiper Seal
Polyseal
Piston, Pull
Back-up Ring
O-ring
O-ring
Back-up Ring
O-ring
Back-up Ring
Rear Gland
Pintail Deflector
End Cap
Tube
Return Gland Assembly
Gland, Return
O-ring
Back-up Ring
O-ring
Back-up Ring
Gland, Pull
Back-up Ring
O-ring
Piston Assembly
Screw
O-ring
Piston
O-ring
Throttle Valve
O-ring
Air Hose Assembly
O-ring
Spring
Self-locking Nut
Bottom Plate
Muffler
O-ring
Screw
Gasket
Retaining Ring
O-ring
Cylinder Head
Quad Ring
Piston, Air
Alcoa Fastening Systems
QTY
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
6
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
1
1
1
1
1
1
15
ITEM
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
PART#
113344
120372
127326
500786
500779
127328
500781
502821
127324
127329
127325
500424
100309
505438
127688
116916
125657
500102
120204
111068
505446
120203
120129
100874
111067
502929
111139
112405
501408
112403
505864
114530
505863
120127
120128
502506
114528
120354
620084
590347
590351
590350
127327
113532
590240
590247
DESCRIPTION
Piston Rod
Cylinder Assembly
Gland Assembly
O-ring
O-ring
Back-up Ring
O-ring
Retaining Ring
Gland
Polyseal
Gland Housing
Screw
Bleed Plug
O-ring
Throttle Arm
Screw
Guard
Screw
Plug
Plug
O-ring
Pin
Screw
Spring
Guide
Ball
Seat
Reservoir Plunger
Quad Ring
Housing/Spacer Assembly
Spring
Plug
Spring
Sleeve
Guide
Ball
Seat
Head Assembly
Sticker
Sticker
Sticker
Sticker
Back-up Ring
Pull Gland Assembly
Sticker
Sticker
99
100
501086
502053
Back-up Ring
Oval Point Set Screw
QTY
1
1
1
1
1
1
1
1
1
1
1
2
3
4
1
1
1
4
1
1
3
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
Model 246 Tool
Alcoa Fastening Systems
TROUBLESHOOTING
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.
5
a) Worn or damaged Gland Assembly (54): Inspect
Variseal (61), O-rings (30, 55 & 56), and Back-up
Ring (29). Replace if necessary.
6. Hydraulic fluid leaks at rear of Pull Piston (11)
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
a) Worn or damaged Rear Gland (18): Inspect
O-rings (14 & 16) and Back-up Rings (15 & 17).
Replace if necessary.
7. Hydraulic fluid leaks at front of Pull Piston (11).
Tool fails to operate when trigger is depressed.
a) Worn or damaged front seal: Inspect Polyseal
(10). Replace if necessary.
a) Air line not connected
b) Throttle Valve O-rings (37 & 39), worn or
damaged.
c) Throttle Valve Cable (2) is broken.
2
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.
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
9. Air leaks at air Cylinder Head (49).
a). Worn or damaged O-ring (48): Replace if
necessary.
ACCESSORIES
Pintail stripped and/or swaged collar not ejected.
Stall Nut (Fig.7)
Assembly Bullet (Fig.2)
Pintail Bag
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
Hydraulic fluid exhausts with air or leaks at base of
handle.
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 (99).
Replace if necessary.
16
-
120824
120792
125655
Model 246 Tool
Alcoa Fastening Systems
L IMITED 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
MANUFACTURED BY HUCK:
NOT
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.
For the Long Haul™
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 Aerspace centers, where they provide
a ready source of AFS fasteners, installation tools,
tool parts, and application assistance.
Alcoa Fastening Systems world-wide locations:
Americas
Far East
Europe
Alcoa Fastening Systems
Alcoa Fastening Systems
Alcoa Fastening Systems
Alcoa Fastening Systems
Aerospace Products
Tucson Operations
3724 East Columbia
Tucson, AZ 85714
800-234-4825
520-747-9898
FAX: 520-748-2142
Industrial Products
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
800-278-4825
845-331-7300
FAX: 845-334-7333
Industrial Products
Australia Operations
14 Viewtech Place
Rowville, Victoria
Australia 3178
03-764-5500
Toll Free: 008-335-030
FAX: 03-764-5510
Industrial Products
United Kingdom Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952-290011
FAX: 0952-290459
Alcoa Fastening Systems
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
Industrial Products
Latin America Operations
Avenida Parque Lira. 79-402
Tacubaya Mexico, D.F.
C.P. 11850
FAX: 525-515-1776
TELEX: 1173530 LUKSME
Alcoa Fastening Systems
NOTICE: The information contained in this
publication is only for general guidance with
regard to properties of the products shown
Aerospace Products
France Operations
Clos D’Asseville
BP4
95450 Us Par Vigny
France
33-1-30-27-9500
FAX: 33-1-34-66-0600
Certified to
ISO 9001:2008
Industrial Products
Waco Operations
PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
800-388-4825
254-776-2000
FAX: 254-751-5259
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.
Alcoa Fastening Systems
Industrial
Products
Industrial
Products
Certified to
ISO 14001:2004
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, upto-date data and information regarding each
application and/or use of such products.
HWB898 1003-5M
One Great ConnectionSM
© 2003 Alcoa Fastening Systems
1 Corporate Drive, Kingston, NY 12401 • Tel: 800-431-3091 • Fax: 845-334-7333 • www.alcoafasteningsystems.com