507-2, & 507SP - Applifast

506 and 507 Series ToolingAlcoa Fastening SystemsPRINCIPLE OF OPERATION!WARNINGThese flats were designed toprovide a passage for hydraulic fluid from PULLside to RETURN side of piston, “unloading” or“dumping” the pressurized fluid back to tank.When the trigger is released, the solenoid isde-energized and the valve directs pressurizedfluid to rear side of the piston and allows fluid onPULL side to flow back to lank.HUCK RECOMMENDS THAT ONLY HUCKHYDRAULIC POWERIGS BE USED AS THEPOWER SOURCE FOR HUCK INSTALLATION EQUIPMENT. HYDRAULIC POWERUNITS THAT DELIVER HIGH PRESSUREFOR BOTH “PULL” AND “RETURN” ANDARE NOT EQUIPPED WITH RELIEFVALVES ARE SPECIFICALLY NOT RECOMMENDED AND MAY BE DANGEROUS.This causes piston and collet to move forwardand pushes nose assembly and tool off theswaged (installed) fastener. Nose assembly jawrelease contacts jaws, causing them to open andrelease the broken-off pintail. The ejector rodhydraulically ejects the pintail out the front of thenose assembly. When the piston reaches theend of its RETURN stroke, pressure is built upcausing the POWERIG-idler valve (except onModels 910 and 911) to go to idling pressure.Idling pressure keeps the tool piston and noseassembly collet, jaws, etc. in the forward positionready for the next installation cycle.Refer to Figure 1When tool hoses and cord are connected toPOWERIG hoses and control cord, PULL andRETURN strokes of tool are controlled by atrigger in the handle. When the trigger isdepressed, a solenoid operated valve in thePOWERIG directs pressured hydraulic fluidthrough the FILL hose to the front side ofpiston, and allows fluid on the RETURN side toflow back to tank. The piston and nose assemblycollet moves rearward causing follower 0-ringsand/or spring to impart a forward motion to thefollower. If tool and nose assembly is in positionon a fastener pin and collar, this forward motioncauses the jaws to clamp onto pintail of fastenerand installation cycle commences. Clampingpressure is applied to the sheets. The anvil isforced forward, swaging the collar into lockinggrooves of the fastener. When the anvil hits thesheet, continued pull causes the pintail to breakoff. When the piston reaches the end of its PULLstroke, it uncovers flats on the rear end of theunloading valve.A flat on the front end of the unloading valve wasdesigned to provide a passage for hydraulic fluidfrom RETURN side of piston to PULL side ofpiston and back to tank.8

506 and 507 Series ToolingAlcoa Fastening SystemsPREPARATION FOR USECAUTIONCAUTIONKEEP DIRT AND OTHER FOREIGN MATTEROUT OF THE HYDRAULIC SYSTEMS OF THETOOLS, HOSES, COUPLERS AND POWERIG.DO NOT LET HOSE FITTINGS AND COUPLERS CONTACT A DIRTY FLOOR ORUNCLEAN WORKING SURFACE. FOREIGNMATTER IN HYDRAULIC FLUID WILL CAUSETHE TOOL AND POWERIG VALVES TO MALFUNCTION.HOSE COUPLERS MUST BE COMPLETELYSCREWED TOGETHER TO INSURE THATBALL CHECKS IN BOTH NIPPLE AND BODYARE COMPLETELY OPEN. (IMPROPERLYASSEMBLED COUPLERS WILL CAUSEOVERHEATING AND MALFUNCTIONS INBOTH TOOL AND POWERIG.) HAND TIGHTEN COUPLERS-DO NOT USE A PIPEWRENCH.POWER SOURCE CONNECTIONS4. Connect trigger cord to POWERIG cord.Coat hose fitting threads with a non-hardeningTeflonTM thread compound such as Slic-tite.TM(Slic-tite is manufactured by Lake Chemical Co.and is available from Huck as part number503237.) DO NOT use Teflon tape on hose fitting threads.5. Turn POWERIG to “ON” and depress andrelease trigger a few times to circulatehydraulic fluid. Observe action of tool. Checkfor fluid leaks.6. Attach the proper Nose Assembly to the toolper instructions on the Nose Assembly DataSheet.1. Screw PULL pressure hose, part number104490, with coupler nipple, part number103391, into tool port “P.” Screw RETURNpressure hose, part number 104490, withcoupler body, part number 103392, intotool port ‘‘R.’’NOTICEModel 506 H.I.T. with a serial number 1389 andabove has a deeper pocket in the end of thepiston rod. This allows clearance for the pintail.A longer jaw follower CAP, P/N 122690 isrequired in the nose assembly. CAP, P/N102881 is required with previous tools.2. Use a Huck POWERIG or equivalent thathas been prepared for operation per applicable instruction manual. Cheek bothPULL and RETURN pressures and adjustas necessary to match installation tool perTable 1. Gage Set-up, part numberT-10206(old) & T-124833(new), for checkingPOWERIG pressures is available from Huck.Model 507 H.I.T. with a serial number 0847 andabove has a deeper pocket in the end of thepiston rod. This allows clearance for the pintail.A longer jaw follower CAP, P/N 122686 isrequired in the nose assembly. CAP, P/N104411 is required with previous tools.3. Turn POWERIG to “OFF” and couple toolhoses to POWERIG hoses. Be sure thatthe larger hoses run from tool port “P” toPOWERIG port “P” and the smaller hosesrun from tool port “R” to POWERIG port “R”.Refer to the applicable Nose Assembly DataSheet for nose assembly components.9

506 and 507 Series ToolingAlcoa Fastening SystemsOPERATING INSTRUCTIONSCAUTION4. Push nose assembly onto the pin until thenose assembly anvil stops against the collar.Tool and nose assembly must be held atright angles (900) to the work.REASONABLE CARE OF INSTALLATIONTOOLS BY OPERATORS IS AN IMPORTANTFACTOR IN MAINTAINING TOOL EFFICIENCYAND IN REDUCING REPAIR DOWN-TIME. DONOT ABUSE THE TOOL BY DROPPING IT.USING IT AS A HAMMER OR OTHERWISECAUSING UNNECESSARY WEAR AND TEAR.BE SURE THERE IS ADEQUATE CLEARANCE FOR THE TOOL AND OPERATOR’SHANDS BEFORE PROCEEDING. DO NOTCONNECT TOOL HOSES TO EACH OTHERAND USE AS A HANDLE FOR CARRYING!WARNINGDO NOT PULL ON A PIN WITHOUT ACOLLAR. IF A PIN IS PULLED WITHOUT A COLLAR, THE PIN WILL EJECTFORCIBLY WHEN THE PINTAILBREAKS OFF.5. Depress tool trigger to start installation cycle.6. When forward motion of nose assembly anvilstops and pintail breaks off, release trigger.Tool will go into its return stroke, push offthe installed fastener and eject the pintail.To install a HUCKBOLT Fastener:1. Check work and remove excessive gap.(Gap is the space between sheets. Gap isexcessive if not enough pintail sticks throughthe collar for the nose assembly jaws to grabonto).7. The tool and nose assembly is ready for thenext installation cycle.2. Put HUCKBOLT pin in hole.3. Slide HUCKBOLT collar over pin. (Thebeveled end of the collar must be towardsthe nose assembly and tool.)10

506 and 507 Series ToolingAlcoa Fastening SystemsMAINTENANCE AND REPAIRPOWERIG MaintenancePREVENTIVE MAINTENANCENOTEFor supplementary information refer toTroubleshooting Chad, Parts Lists, andDisassembly and Assembly procedures inthis Section.Maintenance instructions and repair proceduresare in the appropriate POWERIG InstructionManual.System InspectionAt regular intervals, depending on use, replaceall 0-rings and hack-up rings in the tool. SpareParts Kits should be kept on hand. (See Table 4and SPARE PARTS AND SPARE PARTS KITS).Inspect cylinder bore, piston and piston rod andunloading valve for scored surfaces, excessivewear or damage, and replace as necessary.Tool MaintenanceOperating efficiency of the installation tool isdirectly related to performance of the completesystem, including the tool with nose assembly,hydraulic hoses, trigger and control cord, andPOWERIG. Therefore, an effective preventivemaintenance program includes scheduledinspections of the system to detect and correctminor troubles.Nose Assembly MaintenanceDaily cleaning of the nose assembly is recommended. This can usually he accomplished bydipping nose assembly in mineral spirits, orother suitable solvent, to clean jaws and washaway metal chips and dirt. If more thoroughcleaning or maintenance .s necessary, disassemble the nose assembly. Use a sharp pointed“pick” to remove imbedded particles from thepull grooves of the jaws. Reassemble perinstructions on the applicable Nose AssemblyData Sheet.1. Inspect tool and nose for external damage.2. Verify that hydraulic hose fittings andcouplings and electrical connections aresecure.3. Inspect hydraulic hose for signs of damage oraging. Replace hose at six-month to one-yearintervals, depending on use.4. Inspect tool, hose, and POWERIG duringoperation to detect abnormal heating, leaks.or vibration.11

506 and 507 Series ToolingAlcoa Fastening SystemsTROUBLESHOOTINGdefective circuit or part is located. Wherepossible, substitute known good parts forsuspected bad parts. Use a Troubleshooting Chartas an aid in locating and correcting it.Always check out the simplest possible cause of amalfunction first. For example, a switch turnedoff or a power cord not connected. Then proceedlogically, eliminating each possible cause until theTable 2. Troubleshooting ChartTROUBLEPROBABLE CAUSEA. Tool fails to operateInoperative Powerig.Check power source to Powerrig. Troubleshoot Powerig.Loose or disconnected controlcord.Check and tighten securely.Defective auxiliary trigger assembly.Replace trigger assembly.Loose or faulty hydraulic hosecouplings.Check and tighten securely orreplace faulty couplings.B. Tool operates in reversestops in back positionReversed hydraulic hose connections between Powerig andTool.Check and connect hose connections.C. Tool leaks hydraulic oilDepending on where leakoccurs, defective or worn0-rings, or loose hydraulichose connection at Tool.Check and replace 0-rings andback-up rings, or tightenthreaded connectors of hydraulic hose.D. Hydraulic oil overheatsPowerig not operating properly.Troubleshoot Powerig.Hydraulic couplers not completely tightened.Tighten hydraulic couplers.Low or erratic hydraulic pressure supply.Troubleshoot Powerig.Defective or excessively wornpiston 0-ring in Tool.Replace 0-ring and back-upring.Excessive wear or scoring ofsliding surfaces of Tool parts.Check and replace defectivepartSolenoid pin too short — wornor peened over.Replace solenoid pin.E. Tool operates erraticallyand fails to install fastenerproperly12CORRECTIVE ACTION

506 and 507 Series ToolingAlcoa Fastening SystemsTROUBLESHOOTING (CONT.)Table 2. Troubleshooting Chart (continued)TROUBLEPROBABLE CAUSECORRECTIVE ACTIONOperator not sliding nosecompletely onto fastener pintail.Instruct operator in properinstallation methods.Incorrect fastener length.Use correct length fastener.Worn or damaged jaw segments.Check and replace jaw set.Metal chips accumulated inpull grooves of jaw segments.Clean jaw segments.Excessive sheet gap.Eliminate excessive gap.Improper Tool operation.See Trouble E.Scored anvil in nose.Check and replace anvil.H. Tool “hangs up” onswaged collar of HUCKBOLT FastenerImproper Tool operation.See Trouble E.I.Improper Tool operation.See Trouble E.Pull grooves on fastenerstripped.See Trouble F.Improper operation of jawfollower.Check spring and install correct number of follower0-rings. Clean before reassembling.F. Pull grooves on fastenerpintail stripped during pullstrokeG. Collar of HUCKBOLTFastener not completelyswagedPintail of fastener fails tobreakJ. Jaw segments do notmaintain proper positionin collet13

506 and 507 Series ToolingAlcoa Fastening SystemsDISASSEMBLY AND ASSEMBLY(Lubriplate is manufactured by FiskeBrothers Refining Co. and is available inmost localities. A handy tube ofLubriplate 130AA is available from Huckas part number 502723).GENERALDuring disassembly and assembly, take the following precautions to avoid damaging tool orcomponents:DISASSEMBLY AND ASSEMBLYTOOLS(a) Always work on a clean surface.(b) Use relatively soft materials, such as brass,aluminum or wood, to protect tool whenapplying pressure.A special Spanner Wrench, Part No. 110362, isavailable from Huck to aid in the disassemblyand assembly of Locking Ring, reference No.11. Piston Rod Guides, Part No. 102884 (506)and Part No. 102862 (507) are available to prevent damage to piston rod seals when assembling the piston.(c) Apply a continuous strong pressure, ratherthan sharp blows, to disassemble or assemble a component. An arbor press providessteady pressure to press a component in orout.Standard hand tools such as wrenches, drifts,copper or lead hammers, screwdrivers, socketscrew hexagon keys, long forceps (tweezers),etc. Which can be purchased at most local supply firms are required. If possible, an arborpress and vise with soft jaws should be available. Standard tools available front Huck areshown in Table 3.(d) Never continue to force a component if it“hangs.up” due to misalignment. Reverse theprocedure to correct misalignment and startover.(e) Smear Lubriplate 130AA ,T.M or equivalent,on 0-rings and mating surfaces to aidassembly and prevent damage to 0-rings.Table 3.Standard Tools Available From Huck And Their UsePartNo.DescriptionRef. No.Used onPart No.502446502293502867502868502856Hex Key, 5/16 across flatsHex Key, 3/32 across flatsTruarc Pliers, Waldes Kohinoor, Inc. #0600Truarc Plier, Waldes Kohinoor, Inc. #S-6800TRUARC Pliers, Wald. Koh. Inc. 2Locking Ring Wrench1111012611013214

506 and 507 Series ToolingAlcoa Fastening SystemsDISASSEMBLYFor component identification, refer to Figure 1,Sectional View; Figure 2, Exploded View andTable 4, Parts Lists. Numbers in parenthesesare reference numbers shown in Figures 1 and2.4. Screw locking ring (11) part way in. Screwtwo cap screws (4) into cylinder cap (14).Use pry bars under the heads of the screwsto gradually pry cylinder cap (14) out ofcylinder (32).The following procedure is for a completedisassembly. Disassemble only the componentsnecessary to check and replace a damaged Oring, jaw segment or other component.5. Remove unloading valve (19).6. Drain hydraulic fluid from cylinder (32).7. Unscrew hoses (37).NOTEBe sure POWERIG is turned “OFF” whenremoving the nose assembly to clean or replacecomponents. See applicable Nose AssemblyData Sheet for additional instructions.8. Press piston (18) out of cylinder (32). Use anarbor press if one is available.9. Unscrew ejector cartridge using 7/16 socketwrench. Using TRUARC pliers, S-0100,remove retaining ring. Remove spacer.1. REMOVE retaining ring (36). Slide off sleeve(35) and remove split ring (34) segments.Pull nose assembly anvil off and unscrewnose assembly collet assembly.10. Remove retaining ring (33)11. Press nose assembly adapter (31) out ofcylinder (32).2. Unscrew four socket head cap screws (4)and remove four Iockwashers (3). HandleAssembly (2) and Cushion (1) are nowseparated from the Tool.12. Use a small dull-pointed rod to removeO-rings and back-up ring from all components.3. Remove one locator (15) and unscrew locking ring (11) using spanner wrench. Removethe other locator (15).15

506 and 507 Series ToolingAlcoa Fastening SystemsASSEMBLYFor component identification, refer to Figure 1,Sectional View; Figure 2, Exploded View andTable 4, Parts List. (Numbers in parentheses ( )are reference numbers shown in Figures 1 and2.5. Place unloading value (19) in hole in piston(18).6. Press cylinder cap (14) into cylinder (32) sothat the locator scallop in the cap matchesthe scallop in the cylinder.Before assembling tool:7. Place one locator (15) in matching scallops.(Cap can be turned by putting a screw intoone of the tapped holes to use as a handle).(a) Clean components In mineral spirits or othersolvent compatible With 0-ring seals.(b) Clean out O-ring grooves.8. Screw locking ring (11) into cylinder (32)using Spanner wrench.(c) Inspect components for scoring, excessivewear or damage.9. Unscrew locking ring (11) 1/4 turn or lessuntil scallop in locking ring matches scallopin cap. Place locator (15) in matching scallops.(d) Replace O-rings and back-up rings. Be surethat relative positions of the 0-rings andback-up rings are as shown in Figures I and2. Specifications for O-rings, back-up ringsand other standard components are shownin Table 5 so that they may be purchasedlocally.10. Position cushion (1) and handle (2) assembly in place and assemble four socket headcap screws (4) and lockwashers (3). Tightenscrews to 490 inch pounds torque if screwsare plated and 655 inch pounds if screws areunplated.(e) Smear Lubriplate 130AA on O-rings andmating surfaces to prevent damage to Orings and to aid assembly.11. Screw hoses (37) into cylinder (32). Coathose fitting threads with a non-hardeningTeflonT.M. thread compound such as SlictiteT.M. (Slic-tite is manufactured by LakeChemical Co. and is available from Huck aspart number 503237). Do NOT use Teflontape on hose fitting threads.1. Press nose assembly adapter (31) into cylinder (32).3. Place spacer into ejector cartridge. Installretaining ring using TRUARC pliers. Pushpintail ejector (20) into ejector cartridge(23) and screw cartridge into piston (19) rod.Note: Step 4 may be done before assembling pintail ejector and ejector cartridge topiston.12. Screw coupler nipple (38) onto hose (37)assembled into cylinder PORT “P.”13. Screw coupler body (39) onto hose (37)assembled into cylinder PORT “R.” (Note:Tool will malfunction if coupler nipple andbody are not properly assembled.)4. Place Piston Rod Guide (P/N 102834 for506; P/N 102862 for 507) over the threads ofpiston (19) rod and press piston into cylinder(32) and adapter (31).16

506 and 507 Series ToolingAlcoa Fastening SystemsASSEMBLY (CONT.)14. Attach tool hoses to POWERIG hoses andactuate tool a few times to check operationof tool and inspect for leaks caused by damaged O-rings.3. Slide strain relief grommet over cord.15. Assemble split ring (34), sleeve (35) andretaining ring (33) when attaching the noseassembly per instructions on the applicableNose Assembly Data Sheet.5. Assemble leads to rear of switch (5).4. Place cord in handle (2) as shown in Fig.1so that leads come out the switch (5) pocket.6. Push switch (5) into handle (2) and retainwith set screw (6).7. Slide cover (9) over other end of cord.ASSEMBLY — Handle Assembly8. Assemble cap (10) (two-prong plug) to cord,and slide cover over cap.1. Screw body of cord grip (7) into handle.2. Slide cord grip cap over cord.SERVICE NOTES:17

Alcoa Fastening SystemsTable 4 - Parts ListTable 4 - Parts List (cont.)506 and 507 Series Tooling18

506 and 507 Series ToolingAlcoa Fastening SystemsFig. 2Exploded View19

506 and 507 Series ToolingAlcoa Fastening SystemsSPARE PARTS AND SPARE PARTS KITSThe quantity of spare parts that should be kepton hand varies with the application and numberof tools in service. However, Spare Parts Kitscontaining perishable parts such as O-rings,back-up rings, etc. should be kept on hand at alltimes. Parts included in Spare Parts Kits 106641(506) and 106642 (507) are indicated byasterisks (*) in PARTS LIST — Table 4.20

506 and 507 Series ToolingAlcoa Fastening SystemsNOTES:1. Part numbers in the 500000 series are standard parts which generally can be purchased locally.2. O-rings sizes are specified as AS 568 dash numbers. (AS 568 isan AEROSPACE SIZE STANDARD FOR O-RINGS and formerlywas known as ARP.)3. Material for 0-rings is VITON (DuPont) or equivalent.4. Back-up Rings are W.S. Shamban & Co. or equivalent. Series S11248 are single turn Teflon and series S-11109 are spiral Teflon.The dash numbers of both series correspond to the O-ring AS 568dash numbers.21

506 and 507 Series ToolingAlcoa Fastening SystemsRETROFIT OF EARLIER TOOLSReplacement parts, except CYLINDERS andPISTONS, — available for earlier Model 506and 507 Installation Tools. If a replacementcylinder or piston is needed for 506, serial no.below 1389 or 507, serial no. below 0847, theapplicable RETROFIT KIT must be ordered.Optional AccessorySuspension Brackets, PR1734-506 andPR1734-507, are available. When used with abalance spring suspension system, much of thetool’s weight is supported. Operator fatigue isalleviated for longer periods.NOTEPISTON RETROFIT KITS include referencenumbers 16 thru 19 and Cylinder RetrofitKits include reference numbers 32 and 11thru 15. (See Table 4 and Figure 2 for reference numbers.)SERVICE NOTES:22

506 and 507 Series ToolingAlcoa Fastening SystemsFig. 323

506 and 507 Series ToolingAlcoa Fastening SystemsFig. 424 pa

506 and 507 Series Tooling Alcoa Fastening Systems Huck Model 507 (family) Sound Level SEL --- 103 dB (A) peak value 132 dB (C) For an eight hour work day, installing 400 typical Huck fasteners will