Alcoa 516 User manual

01-14-2010
HK269
INSTRUCTION MANUAL
H
HYDRAULIC
YDRAULIC C
COLLAR
OLLAR C
CUTTER
UTTER
MODELS
516, 520, 524, 528, 532,
516, 520, 524, 528, 532,
536, & M524
536, & M524

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
3
C
CONTENTS
ONTENTS
EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . 6
Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . .10-12
Assembly Drawing with Part Number 516 - 536 . . . . . . . 13
Assembly Drawing with Part Number M524 . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
4
S
SAFETY
AFETY
This instruction manual must be read,
with particular attention to the following
safety guidelines, by any person servicing
or operating this tool.
1. Glossary
Notes - are reminders of required procedures.
Bold, Italic type and underlining - empha-
sizes a specific instruction.
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 pro-
cedures.
4. Repairman and Operator must read manual prior to
using equipment. Warning and Caution stick-
ers/labels supplied with equipment must be under-
stood before connecting equipment to any primary
power supply. As applicable, each of the sections
in this manual have specific safety and other infor-
mation.
5. Read MSDS Specifications before servicing the
tool. MSDS Specifications are available from the
product manufacturer or your Huck representative.
6. When repairing or operating Huck installation
equipment, always wear approved eye protection.
Where applicable, refer to ANSI Z87.1 - 2003
7. Disconnect primary power source before perform-
ing maintenance on Huck equipment or changing
Nose Assembly.
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.
9. Mounting hardware should be checked at the
beginning of each shift/day.
10. Make sure proper power source is used at all
times.
11. Release tool trigger if power supply is interrupted.
12. Tools are not to be used in an explosive environ-
ment unless specifically designed to do so.
13. Never remove any safety guards or pintail deflec-
tors.
14. Ensure deflector or pintail collector is installed and
operating prior to use.
15. Never install a fastener in free air. Personal injury
from fastener ejecting may occur.
16. 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.
18. If there is a pinch point between trigger and work
piece, use remote trigger. (Remote triggers are
available for all tooling).
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 ham-
mer. 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.
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.
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 fas-
tener data sheet of correct positioning.
25. Tool is only to be used as stated in this manual. Any
other use is prohibited.
Product complies with requirements
set forth by the relevant European
directives.
Read manual prior to using
equipment.
Eye protection required while
using this equipment.
Hearing protection required while
using this equipment.
WARNINGS - Must be understood to
avoid severe personal injury.
CAUTIONS - show conditions that will
damage equipment and or structure.

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
Huck 500 series Collar Cutters are used to remove the
collars from 1/2 through 1-1/8 installed HUCKBOLT®
Fasteners. These Collar Cutters cut through the
swaged collars. Hydraulic pressure is supplied by
HUCK hydraulic Powerig®s at maximum of 5700 psi.
Collar Cutters are accessories and use installation
tool’s operating switch and hose. An auxiliary switch
and control cord is available separately and is used
where a tool switch is not accessible.
5
D
DESCRIPTION
ESCRIPTION
S
SPECIFICATIONS
PECIFICATIONS
Power Source: Huck POWERIG Hydraulic Unit
Hose Kits: Use only genuine HUCK Hose Kits rated
@ 10,000 psi working pressure.
Max Operating Temp: 125*F (51.7*C)
Max Flow Rate: 2 gpm (7.6 l/m)
Max Inlet Pressure: 5700 psi, (393 bar)
Hydraulic Fluid: ATF meeting DEXRON III, DEXRON
IV, MERCON, Allison C-4 or equivalent specifications.
Fire resistant hydraulic fluid may also be used, and is
required to comply with OSHA regulation 1926.302
paragraph (d): "the fluid used in hydraulic power tools
shall be fire resistant fluid approved under schedule 30
of the US Bureau of Mines, Department of Interior, and
shall retain its operating characteristics at the most
extreme temperatures to which it will be exposed."
MODEL
NO.
COLLAR
REMOVED
INCHES
(millimeters)
LENGTH
INCHES
(millimeters)
WIDTH
INCHES
(millimeters)
HEIGHT
INCHES
(millimeters)
WEIGHT
516 1/2 6.60
(168)
3.40
(86)
4.20
(107)
6.50 lbs
2.9 kg
520 5/8
(16)
6.80
(173)
3.40
(86)
4.20
(107)
6.75 lbs
3.1 kg
524 3/4 7.50
(191)
3.75
(95)
4.50
(114)
8.75 lbs
4.0 kg
528 7/8
(22)
8.00
(203)
4.00
(102)
4.80
(122)
10.75 lbs
4.9 kg
532 19.40
(239)
4.25
(108)
5.50
(140)
14.25 lbs
6.5 kg
536 1-1/8 9.40
(239)
4.25
(108)
5.50
(140)
14.25 lbs
6.5 kg

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
The PULL Pressure hose of an installation tool is con-
nected to a Collar Cutter. Cutting stroke is controlled
by installation tool switch or an auxiliary switch. When
switch is depressed, a solenoid-operated valve in the
Powerig directs pressurized hydraulic fluid through
hose and against Cutter Piston. Piston with Blade
moves forward. When Cutter is positioned on swaged
collar, moving Blade presses collar against stationary
Blade. Cutting begins and continues until Piston stroke
is completed. Opposing force of Blades cuts Collar on
opposite sides.
When cutting is completed, switch is released.
Solenoid is de-energized, and valve releases pressure
from Piston and Blade. Powerig idling valve diverts
hydraulic fluid to reservoir. Return Spring moves Piston
to rear of Cylinder, and Blades are opened. The Cutter
is removed from cut collar and is ready to cut next
swaged collar.
6
P
PRINCIPLE
RINCIPLE
OF
OF O
OPERATION
PERATION
WARNING: Huck recommends that only Huck Powerig Hydraulic
Units be used as a power source for Huck installation equipment.
Hydraulic power units that deliver high pressure for both PULL and
RETURN, AND ARE NOT EQUIPPED WITH RELIEF VALVES ARE
SPECIFICALLY NOT RECOMMENDED AND MAY BE DANGEROUS.
Conditions that require checking and adjusting
output pressures:
1. If tool with higher pressure has been used.
2. When changing collar cutter size.
3. When changing tools, if pressure require-
ments differ.
4. First time startup.
5. After overhauling unit.
6. When troubleshooting.
Preparation for checking pressures:
Prime and bleed hydraulic unit per the applicable
POWERIG® instruction
manual.
WARNING: Huck recommends that only
Huck POWERIG® Hydraulic Units be used
as a power source for Huck Installation
Equipment. Hydraulic power units that
deliver high pressure for both PULL and
RETURN, AND ARE NOT EQUIPPED WITH
RELIEF VALVES ARE SPECIFICALLY NOT
RECOMMENDED, AND MAY BE DANGER-
OUS.
WARNING: Correct PULL and RETURN
pressures are required for operator’s
safety and forCollar Cutter’s func-
tion.Pressure gauges T-124833 and
T-124833CE are available for checking
pressures, see S SPECIFICATIONS
PECIFICATIONS section
and applicable gauge instruction manual.
WARNING: For adjusting the pressure,
see the applicable POWERIG® instruction
manual. Neglecting to verify pressures
may lead to catastrophic failure of hoses,
tool or other part of system. This could
cause severe or fatal injury to anyone
nearby.
WARNING: When hydraulic unit is run-
ning, be sure to connect tool’s hoses to
unit before connecting tool’s control cord
to unit. If a malfunctioning cord switch is
connected first, tool may begin to cycle
unexpectedly. An accidentally cycling tool
could severely injure a hand.
When disconnecting hoses, switch con-
trol cord must be disconnected first,
before disconnecting hoses.
C
CHECKING
HECKING H
HYDRAULIC
YDRAULIC P
PRESSURES
RESSURES

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
7
P
PREPARATION
REPARATION
FOR
FOR U
USE
SE
Note: Where a part number (P/N) is given, Huck
sells that part.
Rub Slic-Tite®* with PTFE thread compound, or equiv-
alent, on pipe plug threads and quick connect fitting.
1. Use Huck POWERIG Hydraulic Unit, or equiva-
lent, that has been prepared for operation per
instruction manual. Check both PULL and
RETURN pressures and, if required, adjust to
pressures given in SPECIFICATIONS section of this
manual.
2. First, turn hydraulic unit to OFF. Then disconnect
power supply from hydraulic unit. Disconnect trig-
ger control system from hydraulic unit.
3. Connect PULL pressure hose, with coupler nipple,
into Cutter. Use only with HUCK supplied hoses
rated at 10,000 psi or greater. Check trigger
assembly for apparent damage or wear. If
required, adjust position of trigger assembly on
return pressure hose. Connect trigger control sys-
tem to hydraulic unit. If auxiliary switch and control
cord is used, installation tool is not required to
actuate powerig. With auxiliary switch and control
cord, the tool hose alone, or an equivalent hose,
may be coupled to cutter. The RETURN pressure
port must be plugged with a steel pipe plug HUCK
Part No. 502375 (3/8-18 NPTF).
4. Connect tool switch cord to Powerig cord, or con-
nect auxiliary switch cord to powerig cord.
5. Turn hydraulic unit to ON. Depress and release
switch a few times to cycle tool and to circulate
hydraulic fluid. Observe action of Cutter and check
for fluid leaks.
WARNING: Correct PULL and RETURN
pressures are required for operator’s safety
and for Installation TooI’s function. Gauge
Set-Up, T-124833 and T-124833CE, Is avail-
able for checking pressures. See Tool
SPECIFICATIONS and Gauge Instruction
Manual. Failure to verify pressures may
result in severe personal injury.
WARNING: Be sure to connect Tool’s
hydraulic hoses to POWERIG Hydraulic
Unit before connecting Tool’s switch con-
trol cord to unit. If not connected in this
order, severe personal Injury may occur.
CAUTION: Do not use TEFLON®* tape on
pipe threads. Pipe threads may cause tape to
shred resulting in tool malfunction. (Slic-Tite
is available in stick form as Huck P/N
503237.)
CAUTION: Do not let disconnected hoses
and couplers contact a dirty floor. Keep
harmful material out of hydraulic fluid. Dirt
in hydraulic fluid causes valve failure In
Tool and In POWERIG Hydraulic Unit.
* Slic-Tite is a registered trademark of LA-CO Industries, Inc.
* TEFLON is a registered trademark of DuPont Corp.
WARNINGS:
Read full manual before using tool.
A half-hour training session with qualified
personnel is recommended before using
Huck equipment.
When operating Huck installation equip-
ment, always wear approved eye protection.
Be sure there is adequate clearance for the
operator’s hands before proceeding.
WARNING: RETURN pressure port on
Powerig must be plugged with a steel 3/8-
18 NPTF (HUCK Part No. 502375) pipe plug
to prevent hydraulic fluid from being dis-
charged.

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
8
General
Operators should receive training from qualified personnel.
To remove installed HUCKBOLT® fastener:
1. Place Collar Cutter over swaged collar. Hold bottom flat against sheet surface.
2. Depress installation tool switch or auxiliary switch. The moving blade cuts through side of collar as
stationary blade is pulled into, and simultaneously cuts, opposite side.
3. Release switch when cut is completed. Return spring pushes the piston back to starting position,
and causes blades to open.
4. Cutter can now be removed from cut collar, and cutting cycle repeated on next swaged collar.
CAUTION: Tool must be centered on col-
lar to assure proper cutting action.
WARNINGS:
●To avoid severe personal injury: Wear approved eye and ear protection.
●Be sure of adequate clearance for Operator’s hands before proceeding with fastener installa-
tion.
●Cutters are not generally insulated for coming into contact with electric power sources.
●Stored gas or fluid energy can pose a hazard.
●There is a risk when using cutters of large dimensions, due to the larger opening of cutting
end.
●Cutter shall not be operated if directed toward the operator or any person.
●Beware of ejection of cutting material or chips; turn head in each operation to avoid exposure.
●Working on brittle material can cause harmful splinter.
●Do not bend cutter to free if stuck.
CAUTIONS: Check Cutter for collar seg-
ments after each stroke. Segments not
removed from Cutter will cause damage
to Cutter and to fastened structure.
WARNING: Cutter must be disconnected
prior to clearing collar segments.
O
OPERATING
PERATING I
INSTRUCTIONS
NSTRUCTIONS
For safe operation. Please read completely

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
9
M
MAINTENANCE
AINTENANCE
Good Service Practices
The efficiency and life of any installation or removal tool
depends upon proper maintenance and good service
practices. Tools should be serviced by personnel who
are thoroughly familiar with them and how they operate.
A clean well lighted area should be available for servic-
ing the tool. Special care must be taken to prevent con-
tamination of hydraulic systems.
All parts must be handled carefully and examined for
damage or wear. Perishable parts such as o-rings and
seals should be kept on hand for replacement whenever
tool is disassembled.
See S SPECIFICATIONS
PECIFICATIONS for fluid type. Dispose of fluid in
accordance with local environmental regulations.
Recycle steel, aluminum, and plastic parts in accordance
with local lawful and safe practices.
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. Appropriate hand tools and
soft materials to protect tools must be available. Only
standard hand tools are required. A half inch brass drift,
wood block and a vise with soft jaws will prevent damag-
ing tool.
Preventive Maintenance
Refer to the applicable section for A ASSEMBLY
SSEMBLY and
D
DISASSEMBLY
ISASSEMBLY. For supplementary information refer to
T
TROUBLESHOOTING
ROUBLESHOOTING and illustrations.
With proper care, the cutter will remove 100 collars
before it may be necessary to replace the blades. The
estimated life of the Collar Cutter is 10,000 cycles or 5
years, depending on service conditions.
System Inspection
Operating efficiency of the cutter is directly related to the
performance of the complete system, including the cut-
ter, hydraulic hoses, trigger assembly and the POW-
ERIG® Hydraulic Unit. Therefore, an effective preventive
maintenance program includes scheduled inspections of
the system to detect and correct minor defects.
1. Inspect cutter for external damage.
2. Verify that hoses, fittings and trigger connections
are secure.
3. Inspect hydraulic hoses for signs of damage.
Replace if required.
4. Inspect cutter, hoses and POWERIG® during oper-
ation to detect abnormal heating, leaks or vibration.
POWERIG® Hydraulic Unit Maintenance
Hydraulic fluid should have a maximum contamination
level of ISO CODE 18/15 or SAE LEVEL 6. Portable fil-
tration on smaller powerigs and maintaining filters on
larger powerigs is recommended. Maintenance and
repair instructions are in applicable POWERIG Hydraulic
Unit instruction manuals.
Cutter Maintenance
At regular intervals, depending upon use, replace all
seals in the cutter. Spare seals and parts should be kept
on hand. Inspect cylinder bore and piston for scored sur-
faces, excessive wear or damage, and replace as neces-
sary.
Notes and Specifications for Standard Parts
All part numbers shown are available from Huck. The
500000 series numbers are standard parts which can
generally be purchased locally.
Needle Valve Adjustment
A needle valve has been designed into the hydraulic
cylinder of some of the cutters. The adjustment provides
for the proper piston RETURN stroke when using various
hydraulic units and hose combinations. Tool is shipped
with the valve set in the closed position.
Needle Valve Adjustment for the 940 POWERIG®
Hydraulic Unit: Turn needle valve clockwise to the closed
position.
Needle Valve Adjustment for the 918 POWERIG®
Hydraulic Unit:
1. Close needle valve clockwise. Depress trigger until
piston stops forward.
2. Open needle valve by turning slightly counterclock-
wise. Jog or activate switch. If valve is correctly
adjusted, piston will return to rear and pump shuts
off. Repeat procedure until cutter cycles normally.
3. If normal cutter operation cannot be attained, close
needle valve completely and start over at 1. Repeat
until requirements are met.
Needle Valve Adjustment Trouble-shooting:
Note: A normal piston cycle is when the piston goes fully
forward and fully back with one actuation of the switch.
Q. Piston partially returns and pump shuts off.
A. Needle valve not open enough.
Q. Piston partially or fully returns and pump will not shut
off.
A. Needle valve is open too far.
* Slic-Tite is a registered trademark of LA-CO Industries, Inc.
* TEFLON is a registered trademark of DuPont Corp.
CAUTIONS:
●Consult MSDS before servicing tool.
●Keep dirt and other material out of hydraulic
system.
●Separated parts most be kept away from dirty
work surfaces.
●Dirt/debris in hydraulic fluid causes failure in
POWERIG® Hydraulic Unit’s valves.
CAUTION: Do not use TEFLON®* tape on pipe
threads. Pipe threads may cause tape to shred
resulting in tool malfunction. (Slic-Tite is avail-
able in stick form as Huck P/N 503237.)
CAUTION: Always replace seals, wipers, and
back-up rings when tool is disassembled for any
reason.

D
DISASSEMBLY
ISASSEMBLY
AND
AND A
ASSEMBLY
SSEMBLY
516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
General
During disassembly and assembly, take the following
precautions to avoid damaging tool or components:
(a) Always work on a clean surface.
(b) Use relatively soft materials, such as brass, alu-
minum or wood, to protect tool when applying
pressure.
(c) Apply a continuous strong pressure, rather than
sharp blows, to disassemble or assemble a com-
ponent. An arbor press provides steady pressure
to press a component in or out.
(d) Never continue to force a component if it “hangs
up” due to misalignment. Reverse the procedure
to correct misalignment and start over.
(e) Smear Lubriplate 130AA ,T. M or equivalent, on O-
rings and mating surfaces to aid assembly and
prevent damage to O-rings. (Lubriplate is manu-
factured by Fiske Brothers Refining Co. and is
available in most localities. A handy tube of
Lubriplate 130AA is available from Huck as part
number 502723).
Disassembly and Assembly Tools
Standard hand tools such as wrenches, drifts, copper
or lead hammers, screwdrivers, socket screw hexa-
gon keys, long forceps (tweezers), etc. Which can be
purchased at most local supply firms are required. If
possible, an arbor press and vise with soft jaws
should be available. Standard tools available from
Huck are shown in Table 3.
This series of Collar Cutters is designed in two slightly
varying configurations. In two smaller sizes, piston
blade slides in from top of cylinder, and pin on side
prevents blade rotation. Larger sizes have blade
pushed into cylinder from bottom, and pin on top pre-
vents rotation.
For component identification, refer to Assembly
Drawings and Parts Lists.
10

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
The following procedure is for complete disassembly.
Disassemble only those parts necessary. Check and
replace damaged/worn components. Always replace
O-rings, wipers, and back-up rings of disassem-
bled subassemblies.
1. Uncouple hydraulic hose at Cutter, and disconnect
electrical control cord.
2. Remove Screw(s) (1) from Blade(s) (2). Remove
blade from Cylinder Body (3).
3. Remove four Flat Head Cap Screws (12) from
Cylinder Head (7), and lift out Keeper Plate (11).
4. Remove Retaining Ring (10) while observing the
above WARNING.
5. Pull on hydraulic Coupler (14) to remove cylinder
bead from cylinder. Unscrew Coupler and Pipe
Nipple (13) from Cylinder Head.
6. On 516 and 520 Collar Cutters, pull assembled
Piston (7) and Blade (6) from Cylinder. Lift Return
Spring (5) out.
7. On 524 and 536 Cutters, remove Shoulder Screw
(9) and Washer (8) while observing WARNING
above. Remove Piston (15) and Spring (5).
8. Pull Piston Blade (6) from cylinder body.
516, 520, 524, 528, 532, 536:
Push Pin (4) through hole and into body.
M524:
Remove Screw (4).
9. Use a small diameter, dull-pointed rod to remove
O-Rings and Back-up Rings from all components.
11
D
DISASSEMBLY
ISASSEMBLY
WARNING: Be sure to disconnect Tool’s
electrical control trigger system from
POWERIG® Hydraulic Unit BEFORE dis-
connecting Tool’s hydraulic hoses from
unit. If not disconnected in this order
before any maintenance or cleaning is
done, severe personal injury may occur.
WARNING: Be sure Powerig is turned
OFF before removing Cutter for cleaning
or for replacing worn or damaged compo-
nents.
WARNING: Hold Piston (17) or Cylinder
Head (7) in Cylinder Body (3) when
Retaining Ring (10) or Shoulder Screw (21)
is removed. Return Spring (5) may cause
either or both to eject from Cylinder.

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
Before assembling tool:
(a) Clean components In mineral spirits or other
solvent compatible With O-Ring seals.
(b) Clean out O-Ring grooves.
(c) Inspect components for scoring, excessive wear
or damage.
(d) Replace O-Rings and Back-up Rings. Be sure
that relative positions of the O-Rings and Back-up
Rings are as shown in Cutter assembly drawing.
(e) Smear Lubriplate 130AA on O-Rings and mating
surfaces to prevent damage to O-Rings and to
aid assembly.
1. Fasten Piston Blade (6) to Piston (17) with Washer
(8) and Shoulder Screw (9). Tighten screw to 390
in./lbs.
2. Drop Return Spring (5) into Cylinder Body (3).
Align slot in blade with Pin (4) hole in Cylinder and
push assembled Piston (15), including Back-up
Rings and O-Rings (15a-15d) and blade into
Cylinder.
3. Depending on which model is being assembled,
install Pin (4) or Screw (4).
4. Attach Pipe Nipple (13) and hydraulic Coupler (14)
to Cylinder Head (7).
5. Push assembled Cylinder Head (7), including
Back-up Rings and O-Rings (7a & 7b), into
Cylinder Body (3). While holding Cylinder Head in
position, install Retaining Ring (10).
6. Install Keeper Plate (11) in Cylinder Head with four
Flat Head Cap Screws (12). Tighten Screws to 75
in./lbs.
7. Hold Body Blade(s) (2) in Cylinder Body while
installing Screw(s) (1). Tighten Screw(s) to 245
in./lbs.
8. Couple hydraulic hose to Cutter, and connect elec-
trical control cord.
12
A
ASSEMBLY
SSEMBLY
WARNING: Do not omit any seals during
servicing, leaks will result and personal
injury may occur.
CAUTION: Do not use TEFLON tape.
WARNING: Tool must be fully assembled
with all components included.

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
126
3
4
7b
7a
7
5
10 11
12 14
13
9
9 ref
8
15d
15c
15b
15a
15
Figure AA
13
ITEM DESCRIPTION QTY 516 520 524 528 532 536
1Cap Screw 1 500069 500069 500069 500077 500078 500077
2Body Blade 1 105042 105042 105045 105051 105057 105057-1
3Body Assembly 1 105017 105021 105025 105029 105033 105033-1
4Guide Pin 1 503523 503523 503523 503532 503532 503532
5Piston Return Spring 1 102693 102693 102693 102590 103104 103104
6Piston Blade 1 105041 105041 104970 105050 105056 105056
7Cylinder Head 1111155 111155 111156 111157 111158 111158
7a O-Ring 1 504634 504634 504636 504638 504639 504639
7b Back-up Ring 1 501155 501155 501157 501159 501160 501160
8Washer 1 104971 104971 104971 105052 105052 105052
9Shoulder Screw 1 503466 503466 503466 503476 503476 503476
10 Retaining Ring 1 500967 500967 500971 502118 502120 502120
11 Keeper Plate 1111151 111151 111152 111153 111154 111154
12 Flat Head Screw 4 504281 504281 504281 504287 504287 504287
13 Pipe Nipple 1 503683 503683 503683 503683 503683 503683
14 Hydraulic Coupler 1 110438 110438 110438 110438 110438 110438
15 Piston 1 105037 105037 104957 105046 105036 105036
15a Back-up Ring 1 502855 502855 502841 502804 502938 502938
15b O-Ring 1 504667 504667 504669 504671 504672 504672
15c Back-up Ring 1 501084 501084 501084 501086 501086 501086
15d O-Ring 1 504551 504551 504551 504553 504553 504553
16 Caution Sticker (not shown) 1 590272 590272 590272 590272 590272 590272
17 Warning Sticker (not shown) 1 590273 590273 590273 590273 590273 590273
18
516, 520, 524, 528,
516, 520, 524, 528,
532, & 536
532, & 536
A
ASSEMBLY
SSEMBLY D
DRAWING
RAWING

14
516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
103104
Spring
117452
Screw
104957
Piston
118510
Cylinder
118762
Piston
Blade
502841
Back-up
Ring
504669
O-Ring
501157
Back-up Ring
504636
O-Ring
500971
Retaining Ring
110438
Hydraulic
Coupler
503683 Pipe Nipple
Ø 3.75
504281
Screw (4)
501084
Back-up
Ring
504551
O-Ring
1.20
104971
Washer
7.00
111152
Keeper
Plate
503466
Screw
111156
Cylinder
Head
118787
eft Blade
118788
Right Blade
2.61
1.78
502493
Screw (2)
Partial Top View
12
2
4
5
15
15a
15b
7a
7b
10
12
11
14
13
9
3
6
7
8
15d
15c
Figure BB
M524
M524
A
ASSEMBLY
SSEMBLY D
DRAWING
RAWING
Assembly also includes:
Caution Sticker 590272 and
WARNING Sticker 590273, which
are not shown.

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
1. Cutter Fails to operate:
(a) Inoperative Powerig - See Powerig Instruction Manual
(b) Loose or disconnected control cord
(c) Defective tool switch assembly or auxiliary switch assembly
(d) Loose or faulty hydraulic hose coupling
2. Cutter blades do not completely cut through collar:
(a) RETURN pressure hydraulic hose connected to cutter
3. Cutter leaks hydraulic fluid:
(a) Depending on where the leak occurs - defective or worn O-Rings and/or loose
hydraulic hose connection at cutter
4. Hydraulic Couplers leak fluid:
(a) Defective or worn O-Ring in coupler body (See Hydraulic Couplings Figure in
A
ASSEMBLY
SSEMBLY section.)
5. Hydraulic Fluid overheats:
(a) Powerig not operating properly - Pump motor rotation reversed
(b) Restriction in hydraulic line
6. Gutter operates erratically and does not cut collar quickly:
(a) Low or erratic hydraulic fluid supply
(b) Defective or excessively worn piston O-Ring in cutter
(c) Excessive wear or scoring of sliding surfaces
(d) Blades are dull or damaged
7. Cutter blades fail to open when switch is released:
(a) Return spring is weak or broken
Always check out the simplest possible cause of a malfunction first. For example, a switch
turned off or a power cord not connected. Then proceed logically, eliminating each possible
cause until the defective circuit or part is located. Where possible, substitute known good parts
for suspected bad parts. Use a Troubleshooting Chart as an aid in locating and correcting it.
15
T
TROUBLESHOOTING
ROUBLESHOOTING

16
516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
Part No. Dash No. Part No. Dash No.
501084 12 501160 233
501086 14 502855 330
501102 111 502841 332
501155 228 502804 334
501157 230 502938 335
501159 232
Part No. Dash No. Part No. Dash No.
504551 12 504639 233
504553 14 504667 330
504438 111 504669 332
504634 228 504671 334
504636 230 504672 335
504638 232
Back-up Rings
O-Rings*
Part No. Description
500069 Cap Screw 1/4-20 X 1/2
500077 Cap Screw 5/16-18 X 1/2
500078 Cap Screw 5/16-18 X 5/8
500967 Retaining Ring
500971 Retaining Ring
502118 Retaining Ring
502120 Retaining Ring
503683 Pipe Nipple 3/8 NPTF
503466 Shoulder Screw 3/8 dia X 1/2
503476 Shoulder Screw 1/2 dia X 5/8
503523 Pin
503532 Pin
504281 Flat Head Cap Screw 10-32 X 3/8
504287 Flat Head Cap Screw 1/4-20 X 1/2
Miscellaneous Parts
* O-Ring material, with the exception of Part
No. 504438 is 90 durometer Viton or equiva-
lent. Part No. 504438 is 75 durometer Viton
or equivalent.
TOOL 516-520 524 528 532-536
KIT
Part No. 112124 112125 112126 112127
Description Part No.
Piston Return
Spring 102693 102693 102590 103104
O-Ring 504634 504636 504638 504639
Back-up Ring 501155 501157 501159 501160
Back-up Ring 501084 501084 501086 501086
O-Ring 504551 504551 504553 504553
Back-up Ring 502855 502841 502804 502938
O-Ring 504667 504669 504671 504672
Spare Parts Kits
The quantity of spare parts that should be kept on hand
varies with the number of tools in service. Spare Parts Kits
containing perishable parts such as O-Rings and Back-up
Rings should always be kept available to replace worn
items.
Also available are:
Auxiliary Electric Trigger Assembly - 113056
Slic-Tite Stick - 503237
Lubriplate 130A - 502723
Never-Seez - 505565
* Slic-Tite is a registered trademark of LA-CO Industries, Inc.
* Never-Seez is a registered trademark of Bostik, Inc.
* Lubriplate is a registered trademark of Lubriplate Lubricants Co.
Part No. Description
502296 Hex Key 3/16
502445 Hex Key 1/4
502294 Hex Key 1/8
502295 Hex Key 5/32
502859 Truarc Pliers 0500
502860 Truarc Pliers S6700
Standard Service Tools

516, 520, 524, 528, 532, 536, M524 Hydraulic Collar Cutters Alcoa Fastening Systems
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 nine-
ty (90) days from the date of original purchase.
Warranty on "non standard or custom manufactured
products": With regard to non-standard products or cus-
tom 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 MER-
CHANTABILITY OR AS TO THE FITNESS OF THE
TOOLING, OTHER ITEMS, NONSTANDARD OR CUS-
TOM MANUFACTURED PRODUCTS FOR ANY PARTIC-
ULAR PURPOSE AND HUCK SHALL NOT BE LIABLE
FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDI-
RECTLY, ARISING FROM THE USE OF SUCH TOOL-
ING, OTHER ITEMS, NONSTANDARD OR CUSTOM
MANUFACTURED PRODUCTS OR BREACH OF WAR-
RANTY 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 man-
ufactured tooling, other items, nonstandard or custom
products found to be defective in specifications, workman-
ship and materials not otherwise the direct or indirect
cause of Buyer supplied molds, material, tooling or fix-
tures. Buyer shall give Huck written notice of claims for
defects within the ninety (90) day warranty period for tool-
ing, 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 not manufactured by
Huck.
HUCK MAKES NO WARRANTY WITH RESPECT TO
THE TOOLING, PART(S) OR OTHER ITEMS MANUFAC-
TURED BY THIRD PARTIES. HUCK EXPRESSLY DIS-
CLAIMS ANY WARRANTY EXPRESSED OR IMPLIED,
AS TO THE CONDITION, DESIGN, OPERATION, MER-
CHANTABILITY OR FITNESS FOR USE OF ANY TOOL,
PART(S), OR OTHER ITEMS THEREOF NOT MANU-
FACTURED BY HUCK. HUCK SHALL NOT BE LIABLE
FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDI-
RECTLY, ARISING FROM THE USE OF SUCH TOOL-
ING, 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 manufactur-
er 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 rea-
son or reasons beyond the control of the Huck or its sup-
pliers.
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 cor-
responding 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 [phone] FAX [phone]
Canada
6150 Kennedy Road Unit 10, Mississauga, Ontario,
L5T2J4, Canada.
Telephone [phone] FAX [phone]
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.

Americas
Alcoa Fastening Systems
Aerospace Products
Tucson Operations
3724 East Columbia
Tucson, AZ 85714
800-234-4825
520-747-9898
FAX: [phone]
Alcoa Fastening Systems
Aerospace Products
Carson Operations
PO Box 5268
900 Watson Center Rd.
Carson, CA 90749
800-421-1459
310-830-8200
FAX: [phone]
Alcoa Fastening Systems
Commercial Products
Waco Operations
PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
800-388-4825
254-776-2000
FAX: [phone]
Alcoa Fastening Systems
Commercial Products
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
800-431-3091
845-331-7300
FAX: [phone]
www.hucktools.com
Alcoa Fastening Systems
Commercial Products
Canada Operations
6150 Kennedy Road, Unit 10
Mississagua, Ontario L5T2J4
Canada
905-564-4825
FAX: [phone]
Alcoa Fastening Systems
Commercial Products
Latin America Operations
Avenida Parque Lira. 79-402
Tacubaya Mexico, D.F.
C.P. 11850
FAX: [phone]
TELEX: 1173530 LUKSME
Far East
Alcoa Fastening Systems
Commercial Products
Australia Operations
14 Viewtech Place
Rowville, Victoria
Australia 3178
03-764-5500
Toll Free: 008-335-030
FAX: [phone]
Europe
Alcoa Fastening Systems
Commercial Products
United Kingdom Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952-290011
FAX: [phone]
Alcoa Fastening Systems
Aerospace Products
France Operations
Clos D’Asseville
BP4
95450 Us Par Vigny
France
33-1-30-27-9500
FAX: [phone]
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 Aerospace centers, where they pro-
vide a 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 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
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, acknowledge-
ments, 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
© 2003 Alcoa Fastening Systems
1 Corporate Drive, Kingston, NY 12401 • Tel: [phone] • Fax: [phone] • E-mail: [e-mail] • www.alcoafasteningsystems.com
Alcoa Fastening Systems world-wide locations:
One Great ConnectionSM
Certified to
ISO 14001:2004
Commerical
Products
Certified to
ISO 9001:2000
Commercial
Products