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Instruction Manual 206 series Hydraulic Installation Tools Makers of Huck®, Marson®, Recoil® Brand Fasteners, Tools & Accessories June 17, 2015 HK1059 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings 2 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Contents EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tool Operation/Installation Sequence. . . . . . . . . . . . . . . . . . . . . . . . 9 Preparation for Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Tool Components Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 Electric Trigger Cord Assemblies with Hydraulic Hoses. . . . . . . . . 15 Air Trigger Assemblies with Hydraulic Hoses. . . . . . . . . . . . . . . . . 16 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Hydraulic Hose & Coupler Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Air Trigger, Hose, & Housing Assembly. . . . . . . . . . . . . . . . . . . . . 20 Electric Trigger, Cord, & Housing Assembly. . . . . . . . . . . . . . . . . . 21 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Kits & Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Safety Instructions 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 without 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. 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. WARNINGS: Must be understood to avoid severe personal injury. CAUTIONS: show conditions that will damage equipment and or structure. Notes: are reminders of required procedures. Bold, Italic type and underlining: emphasizes a specific instruction. 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. 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. 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. Continued on next page... 4 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Safety Instructions (continued) 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. 5 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. HYDRAULIC TOOL SAFETY INSTRUCTIONS: 1. Carry out a daily check for damaged or worn hoses or hydraulic connections and replace if necessary. WARNING: Do not exceed maximum PULL and RETURN settings on tool. 2. Wipe clean all couplers before connecting. Failure to do so can result in damage to the quick couplers and cause overheating. 3. Ensure that couplings are clean and correctly engaged before operation. 4. Use only clean oil and filling equipment. WARNING: Be sure all hose connections are tight. All tool hoses must be connected. 5. 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. 6. Do not inspect or clean the tool while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury. 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Description Huck Models 206- and A206- Hydraulic Installation Tools install various fasteners. These light-weight and compact mini-tools, with their offset nose assemblies, have been specially designed for limited clearance areas. Each tool is complete with hydraulic hoses, couplings and control trigger assembly (air or electric). The tool consists of a cylinder assembly and a piston assembly. The piston has a “dump valve” to relieve hydraulic pressure at end of PULL stroke. Piston rod is off-center to the centerline of piston. Tool clearance is increased by having an off-center piston assembly. An offset nose assembly enhances the tool’s builtin clearance. This provides the maximum clearance obtainable. A nose assembly is attached to the tool’s piston rod using the nose assembly’s draw bar. An anvil holder stop limits nose assembly rotation to 80 degrees. Included with each tool is an extra dump valve. This valve is used when a long-stroke tool is required. The tools are powered by Huck POWERIG® Hydraulic Units, or equivalent, and designed to operate on 5400 to 5700 psi PULL pressure and 2200 to 2400 psi RETURN pressure as supplied by the hydraulic unit. The A206- series is an air triggered tool to be used with Huck Models 956 and 970 Powerig Hydraulic Units, or equivalent. The 206- series is an electric triggered tool designed for use with Models 913H, 918, and 940 Powerig Hydraulic Units, or equivalent. 6 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Specifications POWER SOURCE: Huck POWERIG® Hydraulic Unit WEIGHT: approximately 3.5 lbs (~1.6 kg) HOSE KITS: Use only genuine Huck Hose Kits rated @ 10,000 psi (689.5 BAR) working pressure. HYDRAULIC FLUID: Hydraulic fluid shall meet DEXRON® III, DEXRON VI, MERCON®, Allison C-4 or equivalent Automatic Transmission Fluid (ATF) specifications. Fire-resistant fluid may be used if it is an ester-based fluid such as Quintolubric® HFD or equivalent. Water-based fluid shall NOT be used; serious damage to equipment will occur. 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) DEXRON is a registered trademark of General Motors Corp. MERCON is a registered trademark of Ford Motor Corp. Quintolubric is a registered trademark of Quaker Chemical Corp. PULL CAPACITY: 5825 lbs @ 5700 psi (25.9 kN @ 393 bar) STROKE: TOOL inches (cm) 206-500.500 (1.27) 206-625.625 (1.59) 206-12501.250 (3.18) NOTE: The 206-500 tool can be used with an optional stroke limiter kit part number 130866, which will limit stroke to .375 inches (.95 cm); essentially turning the tool into a 206-375 tool. A D B C P R Figure 1 Tool series A inch (cm) B inch (cm) C inch (cm) D inch (cm) 206-500 206-625 206-1250 2.04 (5.17) 2.24 (5.69) 2.79 (7.08) .63 (1.59) 2.19 (5.55) 1.56 (3.97) 7 206 Series Hydraulic Installation Tools (HK1059) Principle Alcoa Fastening Systems & Rings of First, hydraulic hoses, and then, trigger control cord/ hose are connected to Powerig® Hydraulic Unit. Trigger controls PULL and RETURN strokes of Tool. Trigger is depressed; hydraulic pressure is directed to PULL side of piston and piston moves rearward. Fastener installation begins. Operation piston. It moves forward, and the nose assembly, with tool, is pushed off the installed fastener. At end of Piston’s PULL stroke, the flat of the Dump Valve provides a passage for fluid from PULL side to RETURN side of Piston. When this occurs, pressurized fluid is unloaded (or “dumped”). Fluid circulates back to reservoir of the hydraulic unit. When installation is completed, trigger is released. Hydraulic pressure is directed to RETURN side of Piston Stroke Limiter (if used) Dump Valve Figure 2 PULL RETURN 8 9 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Tool Operation / Installation Sequence Figure 3 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Preparation for Use WARNING: When stroke has been increased, care should be exercised to be sure clearance is allowed for the operator’s hands and the Tool. If clearance is not maintained, severe personal injury could result. Long stroke also increases possibility of structural and Tool damage. WARNING: Read entire manual before using tool. A 30-minute training session with qualified personnel is recommended before using Huck equipment. When operating Huck equipment, always wear approved eye and hearing protection. Be sure there is adequate clearance for the operator’s hands before proceeding. CAUTION: Keep disconnected hoses and couplers and hydraulic fluid free of foreign matter. Contaminated fluid can cause valve failures. Do not use Teflon® tape on pipe threads. Tape can shred, resulting in malfunctions. Loctite® 243™ is available in a .5ml tube from Huck (P/N 508567). Do not abuse this tool by dropping it, using it as a hammer, or otherwise causing unnecessary wear and tear. Never carry the tool by attached hoses. WARNING: Huck recommends that only Huck Powerigs be used to power Huck tools. Hydraulic power units that deliver high PULL and RETURN pressures, but which are not equipped with relief valves, are specifically not recommended and may be dangerous. Set PULL and RETURN pressures as directed in Specifications. Failure to properly set pressures may result in serious personal injury. Huck Pressure Gauge T-124883CE is available, and should be used as indicated in its instruction manual. WARNING: Be sure to connect the tool’s hydraulic hoses to the Powerig before connecting tool’s switch/control cord to the Powerig. If not connected in this order and disconnected in the reverse order, serious personal injury may occur. POWER SOURCE CONNECTIONS nose assembly. Install fasteners in test plate of correct thickness with proper size holes. Inspect installed fasteners. If fasteners do not pass inspection, see Troubleshooting section to locate and correct Tool’s malfunction. Use a Huck Powerig® Hydraulic Unit that has been suitably prepared for operation. 1. Use Huck Powerig Hydraulic Unit that has been prepared for operation per unit’s instruction manual. Check both PULL and RETURN pressures and, if required, adjust to pressures given in Specifications section of this manual. See both hydraulic unit and T-124883CE Instruction manuals before/during checking procedure. Visually inspect for leaks and to verify that End Cap is installed correctly. 7. Operator should receive training on proper use from qualified personnel. SPECIAL NOTES Use the correct nose assembly for your fastener. Remove the Stroke Limiter and install extra Valve (flats to rear of tool). Hoses may be installed in bottom of cylinder or out the back of cylinder, as application requires. After removing hoses, move pipe plugs to hose ports, then reinstall hoses. Rub Loctite®* with PTFE thread compound, or equivalent, on pipe plug threads and quick connect fitting. 2. First, turn hydraulic unit to OFF (918 Powerigs only). Then disconnect power supply from hydraulic unit. Disconnect trigger control system from hydraulic unit. 3. Connect tool hoses to hydraulic unit. If required, adjust position of trigger assembly on return pressure hose. Connect trigger control system to hydraulic unit. MAXIMUM GRIP CONDITIONS AND INCREASING TOOL STROKE 4. Connect hydraulic unit to power supply (air or electric). Turn hydraulic unit to ON. Hold Tool trigger depressed for 30 seconds; depress trigger a few times to cycle tool and to circulate hydraulic fluid. Observe action of Tool and check for leaks. 5. Select nose assembly for fastener to be installed. Disconnect hydraulic unit from power supply; disconnect Tool’s trigger control system from hydraulic unit. Attach nose assembly to Tool. Shipped with the tool is a longer dump valve. To install valve, remove stroke limiter from Tool and replace original unloading valve with longer valve, 119422. Tool will now have .500 stroke. The .500 stroke is required when installing fasteners in maximum grip conditions, and when excessive sheet gap exists. Under normal conditions, Nose Assemblies will install fasteners with standard 206-375 or A206-375. 6. Reconnect Tool’s trigger control system to hydraulic unit; reconnect unit to power supply. Check operation of Teflon is a registered trademark of E. I. du Pont de Nemours and Company. Loctite is a registered trademark of Henkel Corporation, U.S.A. 10 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Operating Instructions Read all of these instructions in order to ensure the safe operation of this equipment. To install a Huck Blind Fastener: This section details installing HuckBolt® and Huck Blind Fasteners. Review all CAUTIONs and WARNINGs prior to installing these fasteners. If the tool malfunctions, consult the Troubleshooting section before attempting any repairs. CAUTION: • BOM blind fasteners will jam in the nose assembly if they are pulled when not in workpiece. WARNING: • Wear approved eye and hearing protection. • Ensure there is adequate clearance for operator’s hands before proceeding with fastener installation. • Be sure that pintail deflector is attached to the tool and directed away from all personnel. • Do not pull on a pin without placing a fastener in a workpiece. Make sure that the collar chamfer is out, toward the tool. Pins eject with great velocity when pintails break off or teeth/grooves strip, which could cause severe injury. • To avoid structural and tooI damage, be sure there is sufficient clearance for the nose assembly at full stroke. • Remove excess gap from between the sheets to permit proper fastener installation and prevent jaw damage. ALL jaw teeth must engage the pintail to avoid damaging the teeth. 1. Place a fastener in the workpiece or in the end of the nose assembly. NOTE: The tool or nose assembly must be held against, and at a right angle (90-degrees) to, the workpiece. NOTE: Reasonable care of tools by operators is an important factor in maintaining efficiency and reducing downtime. 2. Press and hold the trigger until the fastener is installed and the pintail breaks. CAUTION: Ensure the tool has been properly re-assembled prior to use. 3. Release the trigger; the tool will perform its RETURN stroke. The pressure is re-directed; the piston moves forward; and the tool is pushed off the fastener and ready for the next installation cycle. Prior to starting these procedures, be sure to verify the proper direction of the flats on the dump valve. To install a HUCKBOLT Fastener: 1. Place a pin in the workpiece and place the collar over the pin. CAUTION: Remove excess gap from between the sheets to permit proper fastener installation and prevent jaw damage. ALL jaw teeth must engage the pintail to avoid damaging the teeth. NOTE: If the collar has one tapered end, that end must be out toward tool; not next to the sheet. 2. Hold the pin and push the nose assembly onto the pin that is protruding through the collar until the nose anvil touches the collar. 3. Press and hold the trigger until the collar is swaged and the pintail breaks. 4. Release the trigger. The pressure is re-directed; the piston moves forward; and the tool is pushed off the fastener and ready for the next installation cycle. 11 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Maintenance GENERAL √√ Check tools and nose assemblies for damage and air or hydraulic leaks; tighten, repair, or replace if necessary. The operating efficiency of your tool is directly related to the performance of the entire system. Regular inspection and the immediate correction of minor problems will keep the tool operating efficiently, and prevent downtime. A schedule of “preventive” maintenance of the tool, nose assembly, hoses, trigger and control cord, and POWERIG will ensure your tool’s proper operation, extend its life, and reduce the risk of personal injury to those who operate it. √√ Inspect the tool, hoses, and POWERIG during operation to detect abnormal heating, leaks, or vibration. √√ Clean nose assemblies in mineral spirits to clear jaws and rinse metal chips and dirt. For a more thorough cleaning, disassemble the nose assembly. Use a pointed “pick” to remove imbedded particles from the pull grooves of the jaws. NOTE: Huck tools should be serviced only by personnel who are thoroughly familiar with its operation. Clean all parts of any assembly with UNITIZEDTM Jaws in mineral spirits or isopropyl alcohol only; do not let the jaws come in contact with other solvents. Do not let jaws soak; dry them immediately after cleaning. Huck recommends drying other parts before re-assembling. √√ Consult MSDS before servicing tool. √√ Service the tool in a clean, well-lighted area. Take special care to prevent contamination of pneumatic and hydraulic systems. Keep separated parts away from dirty work surfaces. √√ Have available all necessary hand tools—standard and special. WEEKLY √√ Disassemble, clean, and reassemble nose assemblies in accordance with applicable instructions. √√ Carefully handle all parts. Before reassembly, examine them for damage and wear. √√ Check the tool and all connecting parts for damage and fluid/air leaks; tighten or replace if necessary. CAUTION: Replace all seals, wipers, O-rings, and Back-up rings when the tool is disassembled for any reason, and at regular intervals, depending on severity and length of use. √√ Inspect the cylinder bore, piston and rod/extension, and unloading valve for scored surfaces, excessive wear, and damage; replace as necessary. √√ Disassemble and assemble tool components in a straight line. Do NOT bend, cock, twist, or apply undue force. STICKERS Stickers on the tool display safety and pressure-settings information, and must always be legible. For more information on sticker locations and part numbers, see the Sticker Locations figures on the following pages. √√ Have any relevant Huck Spare Parts Service Kits available when servicing the tool; they include important consumable parts. Other components, as experience dictates, should also be available. SPARE PARTS SERVICE KITS Huck Spare Parts Service Kits contain perishable replacement parts for your tool. Huck recommends having the appropriate kit accessible. For more information, see Kits & Accessories. DAILY √√ If a Filter-Regulator-Lubricator unit is not being used, uncouple the air disconnects and add a few drops of hydraulic fluid to the air inlet of the tool. FLUID MAINTENANCE NOTE: If the tool is in continuous use, add a few drops of oil in every 2–3 hours. See Specifications on page 7 for information on approved fluid types. Dispose of fluid in accordance with local environmental regulations. Recycle steel, aluminum, and plastic parts in accordance with local lawful and safe practices. √√ Before connecting an air hose to the tool, bleed the air lines to clear dirt or water. √√ Verify that hoses, fittings, couplings, and electrical connections are secure and free of leaks; tighten or replace if necessary. Teflon is a registered trademark of E. I. du Pont de Nemours and Company. Threadmate is a registered trademark of Parker Intangibles LLC. CAUTION: Do not use TEFLON® tape on pipe threads. Tape can shred, resulting in malfunctions. Threadmate™ is available in a 4oz. tube from Huck (P/N 508517). 12 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Sticker Locations Huck tools are labeled with important stickers that contain safety and pressure-settings information. These stickers must remain on the tools and be legible. Damaged, worn, and missing stickers must be replaced. Sticker locations and part numbers can be found in the following series of figures. A sticker must be ordered and replaced on the tool, in the location shown, if: it becomes damaged or worn; it has been removed from the tool; or replacing the Cylinder. 119851-2 Piston Assy contains: Piston (not available separately) 503810 O-Ring 501114 Back-up Ring 119420 Gland Assy contains: Gland (not available separately) 505758 O-Ring 501105 Back-up Ring 500820 O-Ring 119421 Retaining Ring 119435 Cylinder Assy contains: Cylinder (not available separately) 503802 O-Ring 501106 Back-up Ring 503704 Pipe Plug (2) 590424-5700 WARNING Sticker 590517 HUCK Sticker 118472 Screw 501205 Screw 119423 Stop 119422 Dump Valve 206-500 Style Head Components Figure 4 13 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Sticker Locations 119847 119851-1 Piston Assy Stroke Limiter contains: (206-625 Piston (not available separately) 503810 O-Ring 501114 Back-up Ring ONLY) 119420 Gland Assy contains: Gland (not available separately) 505758 O-Ring 501105 Back-up Ring 500820 O-Ring 119421 Retaining Ring 119435 Cylinder Assy contains: Cylinder (not available separately) 503802 O-Ring 501106 Back-up Ring 503704 Pipe Plug (2) 590424-5700 WARNING Sticker 590517 HUCK Sticker 118472 Screw 501205 Screw 119423 Stop 119422-2 Dump Valve 206-625 Style Head Components 206-625, 206-625-2, A206-625 Figure 5 128136 Piston Assy contains: Piston (not available separately) 503810 O-Ring 501114 Back-up Ring 119420 Gland Assy contains: Gland (not available separately) 505758 O-Ring 501105 Back-up Ring 500820 O-Ring 119421 Retaining Ring 128135 Cylinder Assy contains: Cylinder (not available separately) 503802 O-Ring 501106 Back-up Ring 503704 Pipe Plug (2) 590424-5700 WARNING Sticker 590517 HUCK Sticker 501205 Screw 119423 Stop Figure 6 118472 Screw 206-1250 Style Head Components 128134 Dump Valve 206-1250, A206-1250 14 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Electric Trigger Cord Assemblies with Hydraulic Hoses Figure 7 Hose Assembly (See Table below.) 110439 Female Connector 503431 Reducing Bushing (2) Electric Trigger and Housing Assembly (See Table below.) Cable Tie(s) (See Table below.) 110438 Male Connector 118940 Electric Cord Length (Feet) 13 118940-1 26 118944-3 25 505839 (13) - 118940 13 118944-1 12 - - 206-625-2 118940-2 3 118944-2 2 - - 206-1250 118940 13 118944-1 12 - - Tool Electric Trigger & Housing Assy (see Figure 8) 206-500 206-500-25 206-625 15 Hose Assembly Hose Length (Feet) Cable Tie Clamp Assembly 118944-1 12 - - 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Air Trigger Assemblies with Hydraulic Hoses Figure 8 Hose Assembly (See Table below.) 503431 Reducing Bushing (2) Air Trigger and Housing Assembly 110439 Female Connector (See Table below.) 110438 Male Connector Cable Ties (See Table below.) Air Trigger & Housing Assy Hose Assembly Hose Length (Feet) Cable Tie 118935 118944-1 12 - 118935-1 118944-3 25 505833 (13) A206-625 118935 118944-1 12 - A206-1250 118935 118944-1 12 - Tool A206-375 A206-375-25 16 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Disassembly This procedure is for the disassembly of the tool. Disassemble only those components necessary in order to replace damaged O-rings, Quad-rings, Back-up rings, and worn or damaged components. Always use soft jaw vise to avoid damage to tool. For component identification, see Figures 3–9. WARNING: Be sure to disconnect the tool’s control trigger from the POWERIG® before disconnecting tool’s hydraulic hoses from it. If not disconnected in this order, serious personal injury may occur. 10. Slide Gland from piston rear extension. 11. Remove Dump Valve from piston; remove Stroke Limiter (if used) from rear piston rod. 12. Use a small, dull pointed rod to remove all O-rings and back-up rings from parts. NOTE: Disassemble control trigger systems only when it is necessary to rewire or replace trigger switch. To disassemble the tool: 1. Disconnect Tool’s electric trigger control cord or air trigger control hose from hydraulic power unit, then uncouple Hydraulic Hoses. 2. Unscrew Cap Screw and remove Anvil Retainer, and remove nose assembly from Tool. 3. Cut tape from hoses, being careful not to cut into hoses. 4. Remove Trigger Housing from hoses (for more detailed information, refer to illustrations of applicable trigger assemblies in this manual). 5. Remove both Couplers (male and female) from hoses, and drain hoses into container. 6. Unscrew both hoses (ONLY if servicing or switching hoses; otherwise keep hoses attached to tool.) from Tool’s Cylinder. 7. Unscrew Socket Head Screw using a 5/32 hex key, and remove Retaining Ring. 8. Drain fluid from cylinder into container and discard fluid. 9. Press Piston and Gland from cylinder in two steps as follows: STEP 1. Press against piston rod with a wood block until block contacts front of cylinder (block not shown). STEP 2. Using a brass drift/rod, resume pressing on piston rod until piston rod and gland are free of cylinder (see Figure 9). 17 Figure 9 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Assembly P/N indicates a part that is available from Huck. Prior to re-assembling the tool, Huck recommends: 6. If they have been removed, prepare fittings per instructions in Preparation for Use section, and screw hoses into Cylinder. Cleaning components with mineral spirits or a similar solvent. Inspect them for wear/damage and replace as necessary. CAUTION: Do not use TEFLON® tape on pipe threads. Tape can shred, resulting in malfunctions. Threadmate™ is available in a 4oz. tube from Huck (P/N 508517). NOTE: When re-assembling the tool, always replace seals, wipers, and rings of subassemblies, as well as damaged and defective parts. Take care not to damage rings. 7. Refer to figures 7 and 8 for trigger and hose assembly components. NOTE: Air Trigger Control Assy can be modified to use with 970 Powerig® Hydraulic Unit. Remove Quick Disconnect, 113021, and replace with Male Air Fitting, 503902. Screw 503902 into sub-plate of 970. Using the O-rings, Quad-rings, and Back-up rings from Huck Spare Parts Service Kit (P/N 206-375KIT). Having an extra Service Kit available at all times is advised. WARNING: Make sure the tool has been properly re-assembled prior to use. Failure to do so could result in serious personal injury. Do not omit any seals during servicing; leaks will result and personal injury may occur. 8. Clamp either trigger assembly onto return hose and close to Tool. 9. Secure hoses and cord together with black electrical tape, spacing bands approximately 18 inches apart. 10. First connect hydraulic hoses to Powerig® Hydraulic Unit. Then connect control trigger connector/disconnect to hydraulic unit. Smear LUBRIPLATE® 130-AA (Huck P/N 502723) or SUPER-O-LUBE® (Huck P/N 505476) on all rings, and mating parts to ease assembly. 11.See Preparation for Use for WARNINGS, CAUTIONS, procedure for tool set-up, reference to nose assembly, and checking installed fasteners. See Operating Instructions for safe fastener installion procedure. To re-assemble the tool: 1. Set Cylinder Assem. on a protective support, such as a pipe coupling or a hollow wood block, (FIGURE 5), that will protect the front extension’s threads. The Piston can then slide through front opening of cylinder. 12. If test results are good, Tool is ready for use. LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co. SUPER-O-LUBE is a registered trademark of Parker Hannifin Corp. Threadmate is a registered trademark of Parker Intangibles LLC. 2. Position piston in cylinder so that piston rod is aligned with front opening of cylinder. Push down on piston face (Figure 10). Continue to push until piston stops at bottom of cylinder. Piston rod now extends through front opening. Figure 10 3. Push Dump Valve into small hole in rear of piston. NOTE: Flats on valve must be toward rear of Tool. If using a stroke limiter, slide it onto rear piston rod. 4. Place Gland into cylinder, over the rear piston rod, with the screw hole facing out, until it stops against cylinder shoulder. 5. Screw Retaining Ring into cylinder until it stops. Back ring out 1/4 turn, or less, until Cap Screw can be screwed into gland at nearest retaining ring scallop. Tighten with 5/32 hex key. 18 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Hydraulic Hose & Coupler Set Figure 11 Hydraulic Coupler Set, Huck P/N 110440, contains both 110438 and 110439. O-Ring P/N 504438, and back-up ring P/N 501102, must be replaced if leakage occurs when hydraulic couplings are connected .Use a pick with a long point, approximately .060 in diameter, to lift out rings . These rings are included in the tool service kit . To prevent damage to O-ring, use a fine India stoneto remove any nicks or burrs from diameter and leading edge “A” . 19 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Air Trigger, Hose, & Housing Assembly Figure 7 Hose Assembly (See Table below.) 503431 Reducing Bushing (2) Electric Trigger and Housing Assembly (See Table below.) 110439 Female Connector Cable Tie(s) (See Table below.) 110438 Male Connector Air Trigger, Hose, & Housing Assy Air Trigger & Hose Assy Tubing Air Trigger A206-500 118935 119440 112143 119345 A206-625 118935 119440 112143 119345 A206-1250 118935 119440 112143 119345 Tool 20 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Electric Trigger, Cord, & Housing Assembly Figure 8 Male Connector Housing Clamp Plate Screw Setscrew Cord Strain Relief Trigger Switch Assembly Electric Trigger Cord & Housing Assy Electric Trigger & Cord Assy 118940 Cord Male Connector 120245 120341 110686 118940-1 120245-2 120341-1 110686 118940 120245 120341 110686 206-625-2 118940-2 120245-3 120341-5 110686 206-1250 118940 120245 120341 110686 Tool (from Figure 3e) 206-500 206-500-25 206-625 (above) 21 Trigger Guard 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Troubleshooting Always check the simplest possible cause (such as a loose or disconnected trigger line) of a malfunction first. Then proceed logically, eliminating other possible causes until the cause is discovered. Where possible, substitute known good parts for suspected defective parts. Use this Troubleshooting information to aid in locating and correcting trouble. 1. Tool fails to operate when trigger is pressed. a. Inoperative POWERIG® Hydraulic Unit. See applicable instruction manual. b. Loose air or electric connections. c. Damaged trigger assembly. d. Loose or faulty hydraulic hose couplings. e. Unloading valve not installed in tool. 7. Pull grooves on fastener pintail stripped during PULL stroke. a. Operator not sliding anvil completely onto fastener pintail. b. Incorrect fastener grip. c. Worn or damaged jaw segments. d. Metal particles in jaw segments pull grooves. e. Excessive sheet gap. 2. Tool operates in reverse. a. Reversed hydraulic hose connections between hydraulic unit and tool. 3. Tool leaks hydraulic fluid. a. Defective tool O-rings or loose hose connections at tool. 4. Hydraulic couplers leak fluid. a. Damaged or worn O-rings in coupler body. See Coupler 110440. 5. 11. Pintail of fastener fails to break. a. Improper tool operation. See Trouble 6. b. Pull grooves on fastener are stripped. See Trouble 7. c. PULL pressure too low. d. Worn unloading valve. 6. Tool operates erratically and fails to properly install fastener. a. Low or erratic hydraulic pressure; air in system. b. Damaged or worn piston O-ring in tool. c. Unloading valve installed incorrectly. d. Excessive wear on sliding surfaces of tool parts. e. Excessive wear of unloading valve in tool. & 9. Shear collar on Huck Blind Fastener not driven. a. Improper tool operation. b. Worn or damaged driving anviI in nose assembly. 10. Tool “hangs-up” on swaged collar of HuckBolt Fastener. a. Improper tool operation. See Trouble 6. b. RETURN pressure too low. c. Nose assembly not installed correctly. Hydraulic fluid overheats. a. Hydraulic unit not operating properIy. b. Unloading valve installed incorrectly. c. POWERIG running in reverse (918: 918-5). See unit’s manual. Kits 8. Collar of HuckBolt® Fastener not completely swaged. a. Improper tool operation. See Trouble 6. b. Scored anvil. Accessories Spare Parts Service Kit206-375KIT Includes all perishable O-rings and Back-up rings contained in the Cylinder Head. A spare kit should be kept on hand. 22 Air and Hydraulic Conversion Kit125149 Converts existing tool into the -2 version with 2’ hoses. It includes the hoses, male and female couplers, air hose, and fitting. 206 Series Hydraulic Installation Tools (HK1059) Alcoa Fastening Systems & Rings Limited Warranties Tooling Warranty: Huck warrants that tooling and other items (excluding fasteners, and hereinafter referred as “other items”) manufactured by Huck shall be free from defects in workmanship and materials for a period of ninety (90) days from the date of original purchase. Warranty on “non standard or custom manufactured products”: With regard to non-standard products or custom manufactured products to customer’s specifications, Huck warrants for a period of ninety (90) days from the date of purchase that such products shall meet Buyer’s specifications, be free of defects in workmanship and materials. Such warranty shall not be effective with respect to non-standard or custom products manufactured using buyer-supplied molds, material, tooling and fixtures that are not in good condition or repair and suitable for their intended purpose. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. HUCK MAKES NO OTHER WARRANTIES AND EXPRESSLY DISCLAIMS ANY OTHER WARRANTIES, INCLUDING IMPLIED WARRANTIES AS TO MERCHANTABILITY OR AS TO THE FITNESS OF THE TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS FOR ANY PARTICULAR PURPOSE AND HUCK SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING FROM THE USE OF SUCH TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS OR BREACH OF WARRANTY OR FOR ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Huck’s sole liability and Buyer’s exclusive remedy for any breach of warranty shall be limited, at Huck’s option, to replacement or repair, at FOB Huck’s plant, of Huck manufactured tooling, other items, nonstandard or custom products found to be defective in specifications, workmanship and materials not otherwise the direct or indirect cause of Buyer supplied molds, material, tooling or fixtures. Buyer shall give Huck written notice of claims for defects within the ninety (90) day warranty period for tooling, other items, nonstandard or custom products described above and Huck shall inspect products for which such claim is made. Tooling, Part(s) manufactured by Other Items Huck: and not HUCK MAKES NO WARRANTY WITH RESPECT TO THE TOOLING, PART(S) OR OTHER ITEMS MANUFACTURED BY THIRD 23 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 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 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. One Great Connection SM About Alcoa Fastening Systems & Rings Alcoa Fastening Systems & Rings, a business unit of Alcoa, is a leading worldwide designer and manufacturer of fastening systems and rings, including specialty fasteners, fluid fittings, assembly components, installation systems, and seamless rings for aerospace and industrial applications. Headquartered in Torrance, California, the company has over 8,300 employees at 39 manufacturing and distribution/logistics locations in 13 countries. For more information, visit afsr.alcoa.com. Alcoa Fastening Systems & Rings world-wide locations: Americas 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 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 Far East Europe 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 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. 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 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, acknowledgments, 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 For the Long Haul™ ® © 2015 Alcoa Fastening Systems & Rings 1 Corporate Drive, Kingston, NY 12401 • Tel: 800-431-3091 • Fax: 845-334-7333 • www.alcoafasteningsystems.com
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