INSTRUCTION MANUAL HS24LH...should be done by a qualified repairman trained on Huck procedures. 3. Repairman and Operator must read manual prior to using equipment and understand any

Form HK 102404-22-2004

INSTRUCTION MANUAL

HS24LHHYDRAULIC INSTALLATION TOOL

2

HS24LH Tooling Alcoa Fastening Systems

EU Declaration of ConformityManufacturer:Huck International, Inc., Installation Systems Division, 1 Corporate Drive, Kingston, NY,12401, USA

Description of Machinery:Model numbers HS24LH 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 theabove Directive(s) and Standard(s).

Signature: ___________________________________

Full Name: Henk Rosier

Position: Engineering ManagerInstallation Systems Division

Place: Kingston, New York, USA

Date: August, 2001

Sound LevelsModel: HS24LH

The sound level of the tool cycling without fastener isSound Exposure Level (SEL) = 87.2 dB(A)Background (SEL) = 81.8 dB(A)Peak Value = 92.9 dB(C)

The noise of the fastener being installed in structure isconsidered process noise, not tool noise. Processnoise varies greatly from application to application.Sound measurements of simulated process noise areavailable upon written request from Huck Internationalin Kingston, NY 12401, USA.

Vibration Levels Model: HS24LH

For an eight hour work day, installing 1000 typical Huckfasteners will result in an equivalent weighted RMSvibration level (Aeq) of .83 m/s2.

To calculate the equivalent vibration level for otherquantities of fasteners in an eight hour period, use theformula:

Equivalent Vibration Level, Aeq (m/s2) = (n/480) x .4

where n = number of fasteners in eight hours, and .4(m/s2) = Aeq for 60 seconds.

Test data to support the above information is on file atHuck International, Inc., Kingston, NY, USA. Vibrationmeasurements are frequency weighted in accordancewith ISO 8041 (1990).

3


SAFETY

This instruction manual must be read with particularattention to the following safety guide lines, by anyperson servicing or operating this tool.

1. Safety Glossary

WARNINGS - Must be understood to avoid severe personal injury.

CAUTIONS - show conditions that willdamage equipment and or structure.Notes - are reminders of requiredprocedures.Bold, Italic type and underlining -emphasizes a specific instruction.

2. Huck equipment must be maintained in a safeworking condition at all times and inspected on aregular basis for damage or wear. Any repairshould be done by a qualified repairman trainedon Huck procedures.

3. Repairman and Operator must read manual priorto using equipment and understand any Warningand Caution stickers/labels supplied withequipment before connecting equipment to anyprimary power supply. As applicable, each of thesections in this manual have specific safety andother information.

4. See MSDS Specifications before servicing thetool. MSDS Specifications are available fromyou Huck representative or on-line atwww.huck.com. Click on Installation SystemsDivision.

5. When repairing or operating Huck installationequipment, always wear approved eyeprotection. Where applicable, refer to ANSIZ87.1 - 1989

6. Disconnect primary power source before doingmaintenance on Huck equipment.

7. If any equipment shows signs of damage, wear,or leakage, do not connect it to the primarypower supply.

8. Make sure proper power source is used at alltimes.

9. Never remove any safety guards or pintaildeflector.

10. Never install a fastener in free air. Personalinjury from fastener ejecting may occur.

11. When using an offset nose always clear spentpintail out of nose assembly before installing thenext fastener.

12. If there is a pinch point between trigger andwork piece use remote trigger. (Remotetriggers are available for all tooling).

13. Do not abuse tool by dropping or using it as ahammer. Never use hydraulic or air lines as ahandle. Reasonable care of installation tools byoperators is an important factor in maintainingtool efficiency, eliminating downtime, and inpreventing an accident which may cause severepersonal injury.

14. Never place hands between nose assembly andwork piece.

15. Tools with ejector rods should never be cycledwith out nose assembly installed.

16. When two piece lock bolts are being usedalways make sure the collar orientation iscorrect. See fastener data sheet of correctpositioning.

�

Product complies with requirementsset forth by the relevant Europeandirectives.

Read manual prior to usingequipment.

Eye protection required whileusing this equipment.

Hearing protection required whileusing this equipment.

4


EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

ADJUSTMENT OF SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

REMOVING ANVIL & THIMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

ASSEMBLY DRAWINGS/PARTS LIST (FIG 1-8) . . . . . . . . . . . . . . . . . .9-16

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

KITS & ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17&18

LIMITED WARRANTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

HUCK FASTENERS WORLD-WIDE LOCATIONS . . . . . . . . . . . . . . . . . . .20

CONTENTS

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SPE

CIF

ICAT

ION

S(H

S24L

H)

• St

roke

:1.3

6 in

• C

apac

ity:

2240

0 lb

s @

700

0 ps

i

• W

eigh

t:20

lbs

• Pu

ll Pr

essu

re: 7

000

psi

• R

etur

n Pr

essu

re: 6

000

psi

INC

HES

MM

6


PREPARATION FOR USE (FOR 5/8” - 16MM)1. Set the Huck POWERIG PULL pressure to 7,000 psi.

and RETURN pressure to 6,000 psi.. (Refer toPOWERIG instruction manual for setting pressures.)

2. Connect the Controller/Manifold to the POWERIGper Controller/Manifold instruction manual.

3. Connect the tool's electrical, air and hydraulic lines tothe Controller/Manifold.

4. Select any tool and fastener in the controller as theHS24 will not appear in the controller’s menu.

5. Change the controller to the following baselinesettings and adjust as necessary.

Controller Swage Pressure: 6,800 psi. Controller Snub Pressure: 2,000 psi.

6. Turn on the POWERIG and run the warm-up cycle onthe Controller one or two times to remove all air fromthe tool and hoses.

7. The HS24LH tool comes with a 5/8” - 16mm anviland thimble installed on tool. (If these have beenremoved from the tool re-install at this time)

8. Test the tool by installing a fastener in washers at theproper grip. Adjust POWERIG and Controllersettings as necessary to obtain a properly swagedfastener.

� WARNING - Be sure to connect tool hoses tohydraulic unit BEFORE connecting toolelectrical switch cord to unit. Hoses andswitch must be connected in this order anddisconnected in the reverse order to preventpossible severe personal injury.

�WARNING - Proper PULL and RETURNpressures are important for proper functionof Installation Tools. Severe personal injuryor damage to equipment may occur withoutcorrect pressures. Huck Pressure GaugeP/N T-10280 (old style) or the new T124833is now available for checking thesepressures using instructions furnished withthe gauge and in applicable POWERIG®Hydraulic Unit instruction manuals. SeeSpecifications.

PRINCIPLE OF OPERATIONWhen the Trigger is depressed and held down,the automatic installation cycle starts. The AirMotor is activated and rotates the Thimble(clockwise), engaging onto the exposed thread ofthe bolt. When the Thimble has engaged apredetermined length of the thread (detected bythe Limit Switch Rod), the Air Motor stops and thePowerig is activated, supplying hydraulic fluid(Pull Pressure) to the rear of the Tool Pistonwhich moves forward to begin the Collar swaging

process. The Swaging Anvil then moves downover the Collar. When a predetermined hydraulicpressure (Pull Pressure) is reached, hydraulicfluid (Return Pressure) is directed to the front ofthe Piston, moving it rearward. The SwagingAnvil then disengages from the Collar. The AirMotor is then activated and rotates the Thimble(counter-clockwise) to disengage the Tool fromthe bolt thread. The Air Motor then stops and thesystem is ready to install the next fastener.

7


ADJUSTMENT OF SWITCHES (FOR 5/8” & 16MM)

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Switches:The HS24 tool uses two limit switches. Limit switch one(LS-1) senses when the tool's actuator rod first touchesthe fastener with approximately .275in/7mm of thefastener engaged in the thimble. This will allow the tool tostart a "snub" cycle. Limit switch two (LS-2) senses thatthere is enough of the fastener engaged by the thimble,approximately .500in/12.7mm to completely swage thecollar.

Set Up:To set limit switches, connect the tool to appropriatemanifold and controller. Turn on all power except for thehydraulic powering. The "tool connected" light should bethe only light illuminated on the controller/manifold.

Setting Limit Switch One:Screw a fastener approximately .300in/7.5mm into thethimble. Loosen the two screws that lock limit switch one(LS-1) in place. Slide the screws forward or rearward untilthe Limit Switch One (LS-1) just illuminates. If necessaryor helpful, move the adjusting screw at the back of theswitch housing in or out until the to the appropriate settingis obtained. Tighten the two screws that lock the limitswitch.

Setting Limit Switch Two:Screw a fastener approximately .525in/13.3mm into thethimble. Loosen the two screws that lock limit switch two(LS-2) in place. Slide the screws forward or rearward untilthe Limit Switch Two (LS-2) just illuminates. If necessaryor helpful, move the adjusting screw at the back of theswitch housing in or out until the to the appropriate settingis obtained. Tighten the two screws that lock the limitswitch.

Fig. A

8


System Inspection

Operating efficiency of the tool is directly related to theperformance of the complete system, including the tool,controller, and POWERIG Hydraulic Unit. Therefore, aneffective preventive maintenance program includesscheduled inspections of the system to detect and correctminor troubles.

• Inspect tool and nose components for external damage.

• Verify that hydraulic hose fittings and electricalconnections are secure.

• Inspect hydraulic hoses for damage and deterioration.Do not use hoses to carry tool. Replace hoses ifdamaged.

• Observe tool, controller, hoses and hydraulic unit duringoperation to detect abnormal heating, leaks or vibration.

POWERIG Hydraulic Unit Maintenance

Refer to the applicable POWERIG instruction manual.Tool Maintenance

Whenever disassembled, replace all seals, wipers andback-up rings in tool and also at regular intervals(depending on severity and length of use). Service Kits,hoses and extra parts should be kept in stock. Inspectcylinder bore, pistons and piston rods for scored surfacesand excessive wear or damage. Replace as necessary.

Nose Components Maintenance

This Tool has a integral nose assembly, at regularintervals, as experience shows, inspect thimble and anvilfor signs of wear. Replace as necessary.

Controller

The Controller is basically maintenance free. Periodicallycheck all fittings and electrical connections.

PREVENTIVE MAINTENANCE

Removing Anvil:

Extend the hydraulic piston/anvil approximately. 3/8".Place wrench Huck P/N: 126645 on the piston flats and a1-11/16" wrench on anvil. Holding the piston, turn anvil toremove.

Removing Thimble:

Remove anvil as previously described. Remove the pipeplug at the back of the switch housing (see figure A). Turnthe thimble until the threaded hole for the locking pin isvisible through the pipe plug hole. Insert a 3/32" hex keyinto the threaded hole and remove the thimble lockingpin. Remove thimble.

Installing Thimble:

With anvil removed, thread thimble into piston until itbottoms. Thread locking pin in until it bottoms, then backoff 1/4 turn. Slowly thread thimble out whilesimultaneously threading the locking pin in and out until itmoves into slot in end of thimble and tighten the lockingpin. The thimble should not be threaded out more than1/4 turn from its bottom position.

Installing Anvil:

With the piston extended 3/8”, place wrench (126645) onpiston flats, thread anvil into piston and tighten with a 1-11/16” wrench. If necessary loctite #242 may be appliedto the anvil threads before installations.

ANVIL & THIMBLE REMOVAL/INSTALLATION

9


FIG

UR

E 1.

H

S24L

H T

OO

LA

SSEM

BLY

DR

AWIN

G

10


FIG

UR

E 2.

12

6601

SW

ITC

HA

SSEM

BLY

DR

AWIN

G

11


FIG

UR

E 3.

12

6570

CYL

IND

ERA

SSEM

BLY

DR

AWIN

G

12


FIG

UR

E 4.

12

6571

PIS

TON

ASS

EMB

LYD

RAW

ING

13


FIG

UR

E 5.

12

6572

EN

DC

AP

ASS

EMB

LYD

RAW

ING

14


FIG

UR

E 6.

12

6602

HYD

RA

ULI

CA

SSEM

BLY

DR

AWIN

G

15


FIG

UR

E 7.

12

6603

HA

ND

LE/W

IRIN

GA

SSEM

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AWIN

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16


FIG

UR

E 8.

12

6604

DR

IVE

ASS

EMB

LYD

RAW

ING

17


TROUBLESHOOTINGAlways check the simplest possible cause of amalfunction first. For example, a loose or disconnectedtrigger line. Then proceed logically and eliminate eachpossible cause until the defect is found. Where possible,substitute known good parts for suspected defectiveparts. Use the following steps as an aid introubleshooting.

1. Tool fails to operate when trigger is pressed.a. Inoperative POWERIG® Hydraulic Unit. See

applicable instruction manual.b. Loose electrical connections.c. Damaged trigger assembly.d. Loose or faulty hose coupling.e. Controller not turned on.

2. Tool operates in reverse. (Hydraulic Piston)a. Reversed hose connections between hydraulic

unit and tool.

3. Tool operates in reverse (Air Motor)a. Reverse air lines at controller.

4. Tool leaks hydraulic fluid.a. Defective tool O-rings or loose connections at tool.

5. Hydraulic couplers leak fluid.a. Damaged or worn O-rings in Coupler Body

Coupler P/N 110440.

6. Tool operates erratically and fails to install fastenerproperly.a. Low or erratic hydraulic pressure - - air in system.b. Damaged or worn Piston seal in tool.c. Excessive wear on sliding surfaces of tool parts.

7. Collar of fastener not completely swaged.a. Improper tool operation - - see No. 6.b. Scored anvil.c. Rig/controller settings not correct.d. Trigger released early.

9. Tool "hangs up" on swaged collar of fastener.a. Improper tool operation - - see No. 6.b. RETURN pressure too low.

SERVICE AND TOOL KITSService Kit - HS24KIT

Piston Wrench - 126645

SERVICE NOTES:

18


SERVICE NOTES:


LIMITED WARRANTIESTooling Warranty: Huck warrants that tooling and otheritems (excluding fasteners, and hereinafter referred as"other items") manufactured by Huck shall be free fromdefects in workmanship and materials for a period ofninety (90) days from the date of original purchase.

Warranty on "non standard or custom manufacturedproducts": With regard to non-standard products orcustom manufactured products to customer'sspecifications, Huck warrants for a period of ninety (90)days from the date of purchase that such products shallmeet Buyer's specifications, be free of defects inworkmanship and materials. Such warranty shall not beeffective with respect to non-standard or custom productsmanufactured using buyer-supplied molds, material,tooling and fixtures that are not in good condition or repairand suitable for their intended purpose.

THERE ARE NO WARRANTIES WHICH EXTENDBEYOND THE DESCRIPTION ON THE FACE HEREOF.HUCK MAKES NO OTHER WARRANTIES ANDEXPRESSLY DISCLAIMS ANY OTHER WARRANTIES,INCLUDING IMPLIED WARRANTIES AS TOMERCHANTABILITY OR AS TO THE FITNESS OF THETOOLING, OTHER ITEMS, NONSTANDARD ORCUSTOM MANUFACTURED PRODUCTS FOR ANYPARTICULAR PURPOSE AND HUCK SHALL NOT BELIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY ORINDIRECTLY, ARISING FROM THE USE OF SUCHTOOLING, OTHER ITEMS, NONSTANDARD ORCUSTOM MANUFACTURED PRODUCTS OR BREACHOF WARRANTY OR FOR ANY CLAIM FORINCIDENTAL OR CONSEQUENTIAL DAMAGES.

Huck's sole liability and Buyer's exclusive remedy for anybreach of warranty shall be limited, at Huck's option, toreplacement or repair, at FOB Huck's plant, of Huckmanufactured tooling, other items, nonstandard or customproducts found to be defective in specifications,workmanship and materials not otherwise the direct orindirect cause of Buyer supplied molds, material, toolingor fixtures. Buyer shall give Huck written notice of claimsfor defects within the ninety (90) day warranty period fortooling, other items, nonstandard or custom productsdescribed above and Huck shall inspect products for whichsuch claim is made.

Tooling, Part(s) and Other Items not manufactured byHuck.

HUCK MAKES NO WARRANTY WITH RESPECT TOTHE TOOLING, PART(S) OR OTHER ITEMSMANUFACTURED BY THIRD PARTIES. HUCKEXPRESSLY DISCLAIMS ANY WARRANTYEXPRESSED OR IMPLIED, AS TO THE CONDITION,

DESIGN, OPERATION, MERCHANTABILITY ORFITNESS FOR USE OF ANY TOOL, PART(S), OROTHER ITEMS THEREOF NOT MANUFACTURED BYHUCK. HUCK SHALL NOT BE LIABLE FOR ANY LOSSOR DAMAGE, DIRECTLY OR INDIRECTLY, ARISINGFROM THE USE OF SUCH TOOLING, PART(S) OROTHER ITEMS OR BREACH OF WARRANTY OR FORANY CLAIM FOR INCIDENTAL OR CONSEQUENTIALDAMAGES.

The only warranties made with respect to such tool, part(s)or other items thereof are those made by the manufacturerthereof and Huck agrees to cooperate with Buyer inenforcing such warranties when such action is necessary.

Huck shall not be liable for any loss or damage resultingfrom delays or nonfulfillment of orders owing to strikes,fires, accidents, transportation companies or for anyreason or reasons beyond the control of the Huck or itssuppliers.

Huck Installation Equipment

Huck International, Inc. reserves the right to makechanges in specifications and design and to discontinuemodels without notice.

Huck Installation Equipment should be serviced by trainedservice technicians only.

Always give the Serial Number of the equipment whencorresponding or ordering service parts.

Complete repair facilities are maintained by HuckInternational, Inc. Please contact one of the offices listedbelow.

EasternOne Corporate Drive Kingston, New York 12401-0250Telephone (845) 331-7300 FAX (845) 334-7333

Canada6150 Kennedy Road Unit 10, Mississauga, Ontario,L5T2J4, Canada.Telephone (905) 564-4825 FAX (905) 564-1963

Outside USA and CanadaContact your nearest Huck International Office, see backcover.

In addition to the above repair facilities, there areAuthorized Tool Service Centers (ATSC's) locatedthroughout the United States. These service centers offerrepair services, spare parts, Service Parts Kits, ServiceTools Kits and Nose Assemblies. Please contact yourHuck Representative or the nearest Huck office listed onthe back cover for the ATSC in your area.

Americas

Alcoa Fastening SystemsAerospace ProductsTucson Operations3724 East ColumbiaTucson, AZ 85714800-234-4825520-747-9898FAX: 520-748-2142

Alcoa Fastening SystemsAerospace ProductsCarson OperationsPO Box 5268900 Watson Center Rd.Carson, CA 90749800-421-1459310-830-8200FAX: 310-830-1436

Alcoa Fastening SystemsCommercial ProductsWaco OperationsPO Box 81178001 Imperial DriveWaco, TX 76714-8117800-388-4825254-776-2000FAX: 254-751-5259

Alcoa Fastening SystemsCommercial ProductsKingston Operations1 Corporate DriveKingston, NY 12401800-431-3091845-331-7300FAX: 845-334-7333www.hucktools.com

Alcoa Fastening SystemsCommercial ProductsCanada Operations6150 Kennedy Road, Unit 10Mississagua, Ontario L5T2J4Canada905-564-4825FAX: 905-564-1963

Alcoa Fastening SystemsCommercial ProductsLatin America OperationsAvenida Parque Lira. 79-402Tacubaya Mexico, D.F.C.P. 11850FAX: 525-515-1776TELEX: 1173530 LUKSME

Far East

Alcoa Fastening SystemsCommercial ProductsAustralia Operations14 Viewtech PlaceRowville, Victoria Australia 317803-764-5500Toll Free: 008-335-030FAX: 03-764-5510

Europe

Alcoa Fastening SystemsCommercial ProductsUnited Kingdom OperationsUnit C, Stafford Park 7Telford, ShropshireEngland TF3 3BQ01952-290011FAX: 0952-290459

Alcoa Fastening SystemsAerospace ProductsFrance OperationsClos D’AssevilleBP495450 Us Par VignyFrance33-1-30-27-9500FAX: 33-1-34-66-0600

For the Long Haul™

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

industrial and Aerspace centers, where they providea ready source of AFS fasteners, installation tools,tool parts, and application assistance.

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

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

and/or the means for selecting such products, and is not intendedto create any warranty, express, implied, or statutory; all warrantiesare contained only in Huck’s written quotations,acknowledgements, and/or purchase orders. It is recommendedthat the user secure specific, up-to-date data and informationregarding each application and/or use of such products.

HWB898 1003-5M

© 2003 Alcoa Fastening Systems

1 Corporate Drive, Kingston, NY 12401 • Tel: 800-431-3091 • Fax: 845-334-7333 • E-mail: [email protected] • www.alcoafasteningsystems.com

Alcoa Fastening Systems world-wide locations:

One Great ConnectionSM

Documents

INSTRUCTION MANUAL HS24LH...should be done by a qualified repairman trained on Huck procedures. 3. Repairman and Operator must read manual prior to using equipment and understand any