Alcoa HUCK HK480 User manual

November 25, 2015
HK480
Makers of Huck®, Marson®, Recoil®
Brand Fasteners, Tools & Accessories
INSTRUCTION MANUAL
507
HYDRAULIC INSTALLATION TOOL

2
507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings

3
507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
CONTENTS
EC DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PRINCIPLE OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL DISASSEMBLY AND ASSEMBLY GUIDELINES . . . . . . . . . . . . 11
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ASSEMBLY DRAWING WITH PART NUMBERS. . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
KITS & ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HYDRAULIC COUPLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ASSEMBLY OF NPTF THREADED COMPONENTS. . . . . . . . . . . . . . . . 16

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507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
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. ReadMSDSSpecificationsbeforeservicingthetool.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.
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.
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.
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...
SAFETY INSTRUCTIONS
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.
Notes: are reminders of required procedures.
Bold, Italic type and underlining: emphasizes a specific instruction.
WARNINGS: Must be understood to avoid
severe personal injury.
CAUTIONS: show conditions that will
damage equipment and or structure.

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507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
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.
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.
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.
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.
SAFETY INSTRUCTIONS (continued)
WARNING: Do not exceed the maximum
PULL or RETURN settings on tool.
WARNING: Be sure all hose connections
are tight. All tool hoses must be connected.

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507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
DESCRIPTION
MAX OPERATING TEMP: 125° F (51.7° C)
MAX FLOW RATE: 2 gpm (7.5 l/m)
PULL CAPACITY: 75,500 lbs @ 5,700 psi
(337 kN @ 393 bar)
MAX PULL PRESSURE: 5,700 psi (393 bar)
MAX RETURN PRESSURE: 2,400 psi (165 bar)
STROKE: 2.5 inches (6.3 cm)
WEIGHT: 43 lbs (19.5 kg)
POWER SOURCE: Huck POWERIG®Hydraulic Unit
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 as
serious damage to equipment will occur.
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.
SPECIFICATIONS
15.5
(39.4)
9.6
(24.4)
2.7
(6.9)
6
(15.2)
Inches
(cm)
INCHES
(cm)
The Huck 507 inline Hydraulic Installation Tool
installs C50L HUCKBOLT®Fasteners and HLC50L
HUCKLOK®Fasteners. When equipped with the proper
(optional) nose assembly, it can install:
-32 (1” diameter) and
-36 (1-1/8” diameter) fasteners.
Each tool has a cylinder and piston assembly. A relief
valve, designed to relieve the hydraulic pressure at
both ends of the stroke, is situated near the piston.
The pintail ejector ejects broken pintails from the nose
assembly. The end of the piston rod is threaded, and
a nose adapter and retaining rings are included for
attaching nose assemblies.
The operating pressures for the 507 tool are:
• PULL: 5400–5700 psi (372–393 bar) and
• RETURN: 2200–2400 psi (152–165 bar)
as supplied by a Huck POWERIG®Hydraulic Unit,
models 940 and 918—or an equivalent hydraulic unit.
The correct PULL and RETURN pressures are
important for the proper function of the tool and Nose
Assemblies, as well as for the safety of the operator.
Huck has available a gauge (P/N T-124833CE) for
checking hydraulic pressures; instructions for its use are
included with the gauge and the POWERIG.
UPDATING OLDER TOOLS
Changes were made to the 507 tool, starting with serial
number 0847. Replacement parts are still available for
the earlier models. If your tool’s serial number is lower
than 0847, Huck recommends that the tool be updated
to the current configuration. Call your Technical Support
representative for the part numbers.
OPTIONAL ACCESSORY
A Suspension Bracket that alleviates operator fatigue
is available from Huck. When the bracket is used with
a balance spring suspension system, much of the
tool’s weight is supported. Contact Huck Customer
Service for the part number and availability. See KITS &
ACCESSORIES.

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507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
PRINCIPLE OF OPERATION
Piston Relief Valve Trigger
Ejector Rod
Hydraulic Hoses
to Powerig
When tool hoses and cord are connected to POWERIG
hoses and control cord, PULL and RETURN strokes of
tool are controlled by a Trigger in the handle.
When the trigger is pressed, a solenoid-operated valve
in the POWERIG directs pressured fluid through the
FILL Hydraulic Hose to the front side of piston, and
allows fluid on the RETURN side to flow back to tank.
The piston and nose assembly collet moves rearward
causing follower O-rings and/or spring to impart a
forward motion to the follower.
If tool and nose assembly is in position on a fastener pin
and collar, this forward motion causes the jaws to clamp
onto pintail of fastener and installation cycle begins.
Clamping pressure is applied to the sheets. The anvil is
forced forward, swaging the collar into locking grooves
of the fastener.When the anvil hits the sheet, continued
pull causes the pintail to break off. When the Piston
reaches the end of its PULL stroke, it uncovers flats
on the rear end of the Relief Valve. These flats were
designed to provide a passage for hydraulic fluid from
PULL side to RETURN side of piston, “unloading”
(“dumping”) the pressurized fluid back to tank.
When the trigger is released, the solenoid is
de-energized and the valve directs pressurized fluid to
rear side of the piston and allows fluid on PULL side to
flow back to tank.
This causes piston and collet to move forward and
pushes nose assembly and tool off the swaged
(installed) fastener. Nose assembly jaw release contacts
jaws, causing them to open and release the broken-off
pintail. The Ejector Rod hydraulically ejects the pintail
out the front of the nose assembly. When the piston
reaches the end of its RETURN stroke, pressure is built
up causing the POWERIG idler valve (except on models
910 and 911) to go to idling pressure. Idling pressure
keeps the tool piston and nose assembly collet, jaws,
etc. in the forward position ready for the next installation
cycle.
A flat on the front end of the relief valve was designed
to provide a passage for hydraulic fluid from RETURN
side of piston to PULL side of piston and back to tank.
When tool hoses and cord are connected to POWERIG
WARNING: Huck recommends that a Huck
POWERIG®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 the PULL and RETURN pressures
as specified in SPECIFICATIONS. Failure to
properly set these pressures may result in
serious personal injury.
Huck Pressure Gauge (P/N T-124883CE) is
available, and should be used as indicated
in its instruction manual.

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507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
PREPARATION FOR USE
NOTE: Model 507 tools with a serial numbers 0847
and higher have a deeper pocket in the end of the
piston rod. This allows clearance for the pintail. A
longer jaw follower cap (P/N 122686) is required in
the nose assembly. Cap P/N 104411 is required for
earlier models of the tool.
POWER SOURCE CONNECTIONS
Apply Parker Threadmate®, Loctite®567, or Slic-Tite®to
male pipe threads per manufacturer’s instructions.
1.Screw PULL pressure hose (P/N 104490), with
coupler nipple (P/N 103391), into tool port “P.” Screw
RETURN pressure hose (P/N 104490), with coupler
body (P/N 103392), into tool port ‘‘R.’’
2.Use a Huck POWERIG (or equivalent hydraulic unit)
that has been prepared for operation per applicable
instruction manual. Check the PULL and RETURN
pressures, and adjust as necessary. Use Huck Gauge
(P/N T-124833CE) to check POWERIG pressures.
3.Turn OFF the POWERIG, and couple the tool hoses
to the POWERIG hoses. (Be sure that the larger
hoses run from tool port “P” to POWERIG port “P” and
the smaller hoses run from tool port “R” to POWERIG
port “R”.).
4.Connect trigger control cord assembly to the
POWERIG cord.
5.Turn ON the POWERIG, and press and release the
trigger a few times to circulate the hydraulic fluid.
Observe action of tool. Check for fluid leaks.
6.Attach the proper Nose Assembly to the tool.
If fasteners do not pass inspection, see TROUBLESHOOTING
to investigate possible causes.
TEFLON is a registered trademark of E. I. du Pont de Nemours and
Company.
Threadmate is a registered trademark of Parker Intangibles, LLC.
Loctite is a registered trademark of Henkel Corporation, U.S.A
Slic-tite is a registered trademark of LA-CO Industries, Inc.
WARNINGS:
- 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.
- Connect the tool’s hydraulic hoses to
the POWERIG®Hydraulic Unit before
connecting the tool’s switch control cord
to it. If not connected in this order, severe
personal injury may occur.
- Correct PULL and RETURN pressures
(see SPECIFICATIONS) are required for
operator’s safety and proper tooI
function. Huck Pressure Gauge (P/N
T-124883CE) is available, and should
be used as indicated in its instruction
manual. Improper pressure settings may
result in severe personal injury.
NO
TE
M
d
l
50
7
t
l
i
th
i
l
b
08
47
CAUTIONS:
Keep disconnected hoses, couplers, and
hydraulic fluid away from dirty surfaces
and free of foreign matter. Contaminated
fluid can cause valve failures in toll and
POWERIG.
Apply Parker Threadmate®, Loctite®567,
or Slic-Tite®to male pipe threads per
manufacturer’s instructions.
Hose couplers must be securely attached
to ensure that the ball checks in the
nipple and the body are completely open.
Improperly assembled couplers will cause
overheating and malfunctions in the tool
and POWERIG. Hand tighten couplers; do
NOT use a pipe wrench.
1
S
PU
LL
h
(
P/
N
10
44
90
)
it
h
CAUTION: Do NOT use Teflon®tape on pipe
threads. Tape can shred and break free into
fluid lines, resulting in malfunctions.

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507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
OPERATING INSTRUCTIONS
TO INSTALL A HUCKBOLT® FASTENER:
1. Check work and remove excessive gap.
NOTE: “Gap” is the space between sheets. It
is excessive if not enough of the pintail sticks
through the collar for the nose assembly jaws to
grasp.
2. Put a HuckBolt pin in the hole.
3. Slide HuckBolt collar over the pin.
NOTE: The beveled end of the collar must be
towards the nose assembly and tool.
4. Push the nose assembly onto the pin until the nose
assembly anvil stops against the collar. The tool
and nose assembly must be held at right angles (90
degrees) to the work.
5. Press the trigger to start the installation cycle.
6. When the forward motion of the nose assembly
anvil stops and pintail breaks off, release the trigger.
The tool will go into its return stroke, push off the
installed fastener, and eject the pintail.
The tool and nose assembly are ready for the next
installation cycle.
CAUTION: Remove excess gap from
between the sheets to permit correct
fastener installation and prevent jaw
damage. ALL jaw teeth must engage pintail
to avoid damaging teeth.
TO
I
NS
TA
LL
A
H
UC
KB
OL
T®
F
AS
TE
NE
R:
WARNINGS:
- Wear approved eye and hearing
protection.
- Ensure adequate clearance for operator’s
hands before installing fasteners.
- Operators should receive training from
qualified personnel.
- 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/collar 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 serious injury.
- Do NOT bend tool to free if stuck.
- Use tool to install fasteners ONLY; never
use tool as a jack/spreader or hammer.

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507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
See SPECIFICATIONS 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.
PREVENTIVE MAINTENANCE
For supplementary information, see TROUBLESHOOTING,
the DISASSEMBLY and ASSEMBLY procedures, and the
ASSEMBLY DRAWING in this manual.
SYSTEM INSPECTION
The operating efficiency of your tool is directly related
to performance of the entire system, including the tool
and nose assembly, hydraulic hoses, control trigger
assembly, and the POWERIG Hydraulic Unit. Therefore,
an effective preventive maintenance program includes
scheduled inspections of the system to detect and
correct minor troubles.
- Inspect the tool and nose daily for damage and wear.
Inspect the tool before each use for leaks.
- Verify that hydraulic hoses, fittings, couplings, and
electrical connections are secure, and free of leaks
and damage. (Replace hoses at six-month to one-year
intervals, depending on use.) Clear air-lines of dirt and
water.
- Inspect tool, hoses, and POWERIG during operation
to detect abnormal heating, leaks, or vibration.
- Service the tool in a clean, well-lighted area. Take
special care to prevent contamination of pneumatic
and hydraulic systems.
- Carefully handle all parts and components. Before
reassembly, examine for damage and wear; replace
when necessary.
- Have available all necessary hand tools (standard and
special); a half-inch brass drift and wood block; arbor
press; and soft-jaw vise. Unsuitable hand tools could
cause tool damage.
- Follow the disassembly and assembly procedures in
this manual. If Huck recommended procedures are
not followed, the tool could be damaged.
- Disassemble and assemble tool components in a
straight line. Do NOT bend, twist, or apply undue
force. Never force a component if it is misaligned;
reverse the procedure to correct the misalignment and
start again.
- Apply continuous steady pressure to components.
An arbor press provides steady pressure to press a
component into or out of an assembly.
- Apply Parker Threadmate®, Loctite®567, or Slic-Tite®
to male pipe threads per manufacturer’s instructions
(to ease assembly and to prevent leaks).
- Smear LUBRIPLATE®130-AA (P/N 502723) or
SUPER-O-LUBE®(P/N 505476) on rings and mating
parts to ease assembly to prevent nicking/pinching
rings on rough/tight spots.
POWERIG MAINTENANCE
Maintenance instructions and repair procedures are in
the appropriate POWERIG Instruction Manual.
TOOL MAINTENANCE
Whenever disassembled, and at regular intervals
depending on use, replace all O-rings and Back-up
rings. Keep Spare Parts Service Kit, 507KIT, on hand.
Inspect cylinder bore, piston, piston rod, and unloading
valve for scored surfaces, excessive wear, and damage;
replace as necessary.
NOSE ASSEMBLY MAINTENANCE
Clean nose assemblies daily in mineral spirits (or other
suitable solvent) 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
For additional information, see the appropriate NOSE
ASSEMBLY DATA SHEET.
Loctite is a registered trademark of Henkel Corporation, U.S.A.
Threadmate is a registered trademark of Parker Intangibles LLC.
LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co
SUPER-O-LUBE is a registered trademark of Parker Hannifin Corp.
Teflon is a registered trademark of E. I. du Pont de Nemours and
Company.
Slic-tite is a registered trademark of LA-CO Industries, Inc.
MAINTENANCE
See
S
for fluid type Dispose of fluid in
CAUTIONS:
- Consult the Material Safety Data Sheet
(MSDS) before servicing tool.
- Keep foreign matter out of the hydraulic
system. Keep separated parts away from
dirty work surfaces.
- Dirt and debris in hydraulic fluid causes
valve failures in tool and POWERIG®.
- Check the Assembly Drawings in this
manual for the proper direction of the
flats on the dump valve.
S
LU
BR
IP
LA
TE
®
1
30
A
A
®
(
A
P/
N
50
27
23
)
CAUTION: Do NOT use Teflon®tape on pipe
threads. Tape can shred and break free into
fluid lines, resulting in malfunctions.
CAUTION: ALWAYS replace all seals,
wipers, and rings when the tool is
disassembled for any reason.

11
507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
GENERAL DISASSEMBLY AND ASSEMBLY GUIDELINES
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,
aluminum, or wood to protect the tool when applying
pressure.
c. Apply a continuous strong pressure, rather
than sharp blows, to disassemble or assemble
a component. 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®130-AA (Huck P/N 502723)
or equivalent, on O-rings and mating surfaces to aid
assembly and prevent damage to O-rings.
A special Spanner Wrench is available from Huck to
aid in the disassembly and assembly of Locking Ring,
reference No. 11. A Piston Rod Guide is available
to prevent damage to the piston rod seals when
assembling the piston. See KITS & ACCESSORIES.
Standard hand tools, such as wrenches, drifts, copper
or lead hammers, screwdrivers, socket screw hexagon
keys, long forceps (tweezers), etc. (which can be
purchased at most local supply firms) are required.
Huck also recommends having available an arbor press
and a vise with soft jaws.
LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.
DISASSEMBLY
This procedure is for complete disassembly of the
tool. Disassemble only those components necessary
to replace damaged rings, and worn or damaged
components. Always replace O-rings, Back-up rings,
and wipers of disassembled sub-assemblies. Always
use a soft-jaw vise to avoid damaging the tool. For
component identification, see Figure 1.
NOTE: Be sure POWERIG is OFF when removing the
nose assembly to clean or replace components. See
applicable Nose Assembly Data Sheet for additional
instructions.
To disassemble the tool:
1. Remove the retaining ring from the split ring. Slide
off sleeve and remove split ring segments. Pull off
the nose assembly anvil and unscrew the nose
collet assembly.
2. Remove the four socket-head screws and
lockwashers from the handle. The handle assembly
and cushion are now separated from the tool.
3. Remove one locator button and unscrew locking
ring using spanner wrench. Remove the second
locator button.
4. Screw the locking ring partially in. Screw two
socket-head screws into the cylinder cap. Use pry
bars under the heads of the screws to gradually pry
the cylinder cap out of the cylinder assembly.
5. Remove the unloading valve.
6. Drain hydraulic fluid from cylinder assembly.
7. Unscrew the hoses.
8. Press the piston out of the cylinder assembly. Use
an arbor press if available.
9. Unscrew the ejector cartridge assembly using a
7/16” socket wrench. Slide the ejector out of the
cartridge assembly. Unscrew the retaining screw
from cartridge assembly using 3/16” allen wrench.
10. Remove the retaining ring.
11. Press the adapter out of the cylinder assembly.
12. Use a small dull-pointed rod to remove the O-rings
and Back-up rings from all components.
NOTE: Disassemble control trigger systems only
when necessary to rewire or replace the switch/
trigger.
The tool has been properly disassembled. Store all
re-usable parts (screws and disassembled components)
in a clean, dry area.
WARNING: Disconnect the tool’s control
trigger system from the POWERIG®
Hydraulic Unit before disconnecting the
hydraulic hoses from it. If not disconnected
in this order, serious personal injury may
occur.

12
507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
For component identification, see Figure 1. Before
re-assembling the tool:
NOTE: When re-assembling the tool, always replace
damaged and defective parts, and all seals, wipers,
and rings of sub-assemblies.
- Inspect components for scoring, excessive wear, and
damage; replace as necessary.
- Clean components in mineral spirits or other solvent
compatible with O-ring seals. Clean O-ring grooves.
- Replace all O-rings, Quad-rings, and Back-up rings.
See Figure 1 for guidance on positioning these rings.
Take care not to damage rings. Use the rings that are
in Spare Parts Service Kit 507KIT.
- Specifications for O-rings, Back-up rings, and other
standard components are shown in Table 5 so that
they may be purchased locally.
- Smear LUBRIPLATE®130-AA (P/N 502723) or
SUPER-O-LUBE®(P/N 505476) on rings and mating
parts to prevent damage and to ease assembly.
- Apply Parker Threadmate®, Loctite®567, or Slic-Tite®
to male pipe threads per manufacturer’s instructions.
To re-assemble the tool:
1. Press nose assembly adapter into the cylinder.
2. Place the O-ring and washer into the ejector
cartridge. Use a 3/16” allen wrench to install the
retaining screw. Push the pintail ejector into the
ejector cartridge. Install O-ring and Back-up ring on
outside of cartridge. Screw cartridge assembly into
piston; tighten with a 7/16” socket wrench.
NOTE: Step 4 can be completed before
assembling pintail ejector and ejector cartridge
to piston.
3. Place Piston Rod Guide (P/N 102862) over the
threads of piston rod and press the piston into the
cylinder and adapter.
4. Place the relief valve in the hole in the piston.
5. Press the cylinder cap into the cylinder so that the
locator scallop in the cap matches the scallop in the
cylinder.
6. Place one locator in matching scallops.
NOTE: The cap can be turned by putting a screw
into one of the tapped holes to use as a handle.
7. Use the spanner wrench to screw the locking ring
into the cylinder.
8. Unscrew the locking ring 1/4 turn (or less) until the
scallop in the locking ring matches the scallop in the
cylinder cap. Place locator in matching scallops.
9. Position the cushion and handle assembly, and
insert four socket-head screws with lockwashers.
Torque the screws to: 490 in-lbs (if screws are
plated) or 655 in-lbs (if not plated).
10. Apply Parker Threadmate®, Loctite®567, or Slic-
Tite®to the hose fitting threads (per manufacturer’s
instructions), and screw the hoses into the cylinder.
11. Screw the coupler nipple onto the hose that is
attached to cylinder port “P”.
12. Screw the coupler body onto the hose that is
attached to cylinder port “R”.
NOTE: The tool will malfunction if the coupler
nipple and body are not properly assembled.
13. Attach the tool hoses to the POWERIG hoses and
actuate the tool a few times to check its operation;
inspect for leaks caused by damaged O-rings.
14. Assemble the split ring, sleeve, and retaining ring
when attaching the nose assembly.
HANDLE ASSEMBLY
1. Screw the body of the cord grip part of the strain
relief into the handle.
2. Slide the strain relief cap over the cord.
3. Slide the strain relief grommet over the cord.
4. Place the cord in the handle so that leads come out
the switch pocket.
5. Assemble the leads to the rear of the switch.
6. Push the switch into the handle and retain with set
screw.
7. Slide the cover (not shown) over the other end of
the cord.
8. Assemble the cap (two-prong plug) to the cord, and
slide the cover over the cap.
ASSEMBLY
Replace all O rings Quad rings and Back up rings
WARNING: Do not omit any seals during
servicing or re-assembly; leaks will result
and serious personal injury can occur.
CAUTION: Do not use TEFLON®tape on
threads. Tape can shred and break free into
fluid lines, resulting in malfunctions.
WARNING: Make sure the tool is properly
re-assembled, with all components included.
CAUTION: Do not use TEFLON®tape on
threads. Tape can shred and break free into
fluid lines, resulting in malfunctions.

13
507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
ASSEMBLY DRAWING WITH PART NUMBERS
505344- Strain Relief
590501-5700 & 590517 Stickers
506085 O-Ring
504 77
Back-up Ring
10 856 Adapter
101577 Split Ring
50389 O-Ring 50 501 Back-up Ring ( )
11013 Locking Ring
110158 Cylinder Cap
101863 Cushion
500136 Socket Head Screw (4) 50 851 Lockwasher (4)
103944 Switch
5016 3 Set Screw
104484 Handle
50 900
Retaining Ring
101578 Sleeve
50087
O-Ring
501167
Back-up Ring
50 7
Retaining
Ring
1 709 Ejector 110577 Piston
117090
Cylinder
Assembly
110161 Relief
Valve
PULL PRESSURE
110940 Control Cord Assembly
110438 Nipple
104589 Locater Button (2)
Ejector Cartridge
Assembly
See Detail below
(Solid Piston 118652 optionally available)
1 3749-4 Hose (2)
R
RETURN PRESSURE
110439 Body
50 430 O-Ring
50 434 Back-up Ring
1 6946 Cartridge
123359 EJECTO
CA T IDGE ASSEMBLY
1 6943 Retaining Screw
500810 O-Ring
501104 Back-up Ring
506614 O-Ring
1 6944 Washer
FIGURE 1

14
507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
TROUBLESHOOTING
1. Tool fails to operate when trigger is pressed.
a. Inoperative POWERIG®Hydraulic Unit. Check
power source. See applicable instruction
manual.
b. Loose or disconnected control cord.
c. Damaged trigger assembly.
d. Loose or faulty hydraulic hose couplings.
2. Tool leaks hydraulic fluid.
a. Defective O-rings or loose hose connections at tool.
3. Hydraulic couplers leak fluid.
a. Damaged or worn O-rings in coupler body.
4. Hydraulic fluid overheats.
a. POWERIG not operating properIy.
b. Hydraulic couplers not completely tightened.
c. Restriction in hydraulic line.
5. Tool operates erratically and fails to install
fastener properly.
a. Low or erratic hydraulic pressure; air in system.
b. Damaged or worn piston/anvil O-ring in tool.
c. Excessive wear on sliding surfaces of tool parts.
d. Relief Valve too short, worn, or peened over.
6. Collar of HuckBolt®Fastener not completely
swaged.
a. Improper tool operation. See Trouble 5.
b. Scored anvil.
7. Tool “hangs-up” on swaged collar of HuckBolt
Fastener.
a. Improper tool operation. See Trouble 5.
b. RETURN pressure too low.
8. Pintail of fastener fails to break.
a. Improper tool operation. See Trouble 5.
b. Pull grooves on fastener stripped. See Trouble 10.
c. PULL pressure too low.
9. Jaw segments do not maintain proper position in
piston.
a. Incorrect amount of follower O-rings. Clean before
reassembling.
10. Pull grooves on fastener pintail stripped during
PULL stroke.
a. Broken pintail not removed from tool.
b. Anvil was not slid completely onto fastener pintail.
c. Incorrect fastener length.
d. Worn or damaged jaw segments.
e. Metal particles accumulated in pull grooves of
jaw segments.
f. Excessive sheet gap.
11. Tool operates in reverse.
a. Reversed hydraulic hose connections between
POWERIG and tool.
12. Anvil will not slide completely over fastener pintail.
a. Broken pintail not removed from tool.
b. Incorrect fastener length.
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.
ASSEMBLY OF NPTF THREADED COMPONENTS
AIR FITTINGS
1) Apply TEFLON®stick to male threads which do
not have pre-applied sealant per manufacturer’s
recommendations. (Proceed to All Fittings step 2)
HYDRAULIC FITTINGS
1) Apply Threadmate™ to male and female threads
which do not have pre-applied sealant per
manufacturer’s recommendations. (Proceed to All
Fittings step 2)
ALL FITTINGS:
2) Tighten to finger-tight condition.
3) Wrench tighten to 2-3 turns past finger-tight condition.
4) Final thread engagement can be checked (optional)
by measuring the dimension from the flange of male
fitting to the end of the thread before assembly
and subtracting the distance under the flange after
assembly.
THREAD SIZE FINAL THREAD ENGAGEMENT AT FULL MAKE-UP
1/8-27 NPTF .235 inch (.59 cm)
1/4-18 NPTF .339 inch (.86 cm)
3/8-18 NPTF .351 inch (.89 cm)

15
507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
KITS &ACCESSORIES
KITS
SERVICE KIT
Use 507KIT when using this tool and when performing
maintenance on it.
CLAMP AND BRACKET KIT (P/N 130029)
This kit contains the following parts, and is shown
below.
PART NO. DESCRIPTION QTY.
130027 Hose Bracket 1
130028 Hose Clamp 1
502492 Button Head Screw 1/4-20 4
500137 Socket-head Cap Screw .38-24 4
ACCESSORIES
Hex Keys
- 5/16” across flats - 502446
(for socket-head screws in the handle)
- 3/32” across flats - 501623
(for setscrew in the trigger switch)
Spanner Wrench - 110362
(to disassemble/assemble the locking ring)
Piston Rod Guide - 102862
(for assembling the piston)
HYDRAULIC COUPLINGS
Huck has created product-specific Spare Parts Service
Kits that contain various perishable parts. The types
and quantities of spare parts that should be available
vary with the application and tools in use. Have the
appropriate kit accessible when using this tool and
when performing maintenance on it.
Huck also recommends having the following
Accessories available when preparing, using, and
performing maintenance on this tool.
TIP: USE AFINE INDIA STONE TO REMOVE
NICKS AND BURRS FROM DIAMETER A AND
LEADING EDGE TO PREVENT DAMAGE TO O-RING.
O-ring (P/N 504438)Back-up ring (P/N 501102)

16
507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
SERVICE NOTES

17
507 Hydraulic Installation Tool (HK480) Alcoa Fastening Systems & Rings
TOOLING WARRANTY:
Huck warrants that tooling and other items (excluding
fasteners, and hereinafter referred as “other items”)
manufactured by Huck shall be free from defects in
workmanship and materials for a period of ninety (90)
days from the date of original purchase.
WARRANTY ON “NON STANDARD OR CUSTOM MANUFACTURED
PRODUCTS”:
With regard to non-standard products or custom
manufactured products to customer’s specifications,
Huck warrants for a period of ninety (90) days
from the date of purchase that such products shall
meet Buyer’s specifications, be free of defects in
workmanship and materials. Such warranty shall not
be effective with respect to non-standard or custom
products manufactured using buyer-supplied molds,
material, tooling and fixtures that are not in good
condition or repair and suitable for their intended
purpose.
THERE ARE NO WARRANTIES WHICH
EXTEND BEYOND THE DESCRIPTION ON THE
FACE HEREOF. HUCK MAKES NO OTHER
WARRANTIES AND EXPRESSLY DISCLAIMS ANY
OTHER WARRANTIES, INCLUDING IMPLIED
WARRANTIES AS TO MERCHANTABILITY
OR AS TO THE FITNESS OF THE TOOLING,
OTHER ITEMS, NONSTANDARD OR CUSTOM
MANUFACTURED PRODUCTS FOR ANY
PARTICULAR PURPOSE AND HUCK SHALL
NOT BE LIABLE FOR ANY LOSS OR DAMAGE,
DIRECTLY OR INDIRECTLY, ARISING FROM
THE USE OF SUCH TOOLING, OTHER ITEMS,
NONSTANDARD OR CUSTOM MANUFACTURED
PRODUCTS OR BREACH OF WARRANTY
OR FOR ANY CLAIM FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES.
Huck’s sole liability and Buyer’s exclusive remedy
for any breach of warranty shall be limited, at
Huck’s option, to replacement or repair, at FOB
Huck’s plant, of Huck manufactured tooling, other
items, nonstandard or custom products found to
be defective in specifications, workmanship and
materials not otherwise the direct or indirect cause
of Buyer supplied molds, material, tooling or fixtures.
Buyer shall give Huck written notice of claims for
defects within the ninety (90) day warranty period for
tooling, other items, nonstandard or custom products
described above and Huck shall inspect products for
which such claim is made.
TOOLING, PART(S) AND OTHER ITEMS NOT MANUFACTURED BY
HUCK:
HUCK MAKES NO WARRANTY WITH
RESPECT TO THE TOOLING, PART(S) OR
OTHER ITEMS MANUFACTURED BY THIRD
PARTIES. HUCK EXPRESSLY DISCLAIMS
ANY WARRANTY EXPRESSED OR IMPLIED,
AS TO THE CONDITION, DESIGN, OPERATION,
MERCHANTABILITY OR FITNESS FOR USE OF
ANY TOOL, PART(S), OR OTHER ITEMS THEREOF
NOT MANUFACTURED BY HUCK. HUCK SHALL
NOT BE LIABLE FOR ANY LOSS OR DAMAGE,
DIRECTLY OR INDIRECTLY, ARISING FROM THE
USE OF SUCH TOOLING, PART(S) OR OTHER
ITEMS OR BREACH OF WARRANTY OR FOR ANY
CLAIM FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
The only warranties made with respect to such tool,
part(s) or other items thereof are those made by the
manufacturer thereof and Huck agrees to cooperate
with Buyer in enforcing such warranties when such
action is necessary.
Huck shall not be liable for any loss or damage
resulting from delays or 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 [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.
LIMITED WARRANTIES

Americas
Aerospace Products
Tucson OperaƟons
3724 East Columbia
Tucson, AZ 85714
800-234-4825
520-747-9898
FAX: [phone]
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PO Box 5268
900 Watson Center Rd.
Carson, CA 90749
800-421-1459
310-830-8200
FAX: [phone]
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PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
800-388-4825
254-776-2000
FAX: [phone]
Industrial Products
Kingston OperaƟons
1 Corporate Drive
Kingston, NY 12401
800-278-4825
845-331-7300
FAX: [phone]
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LaƟn America OperaƟons
Avenida Parque Lira. 79-402
Tacubaya Mexico, D.F.
C.P. 11850
FAX: [phone]
TELEX: 1173530 LUKSME
Far East
Industrial Products
Australia OperaƟons
14 Viewtech Place
Rowville, Victoria
Australia 3178
03-764-5500
Toll Free: 008-335-030
FAX: [phone]
Europe
Industrial Products
United Kingdom OperaƟons
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952-290011
FAX: [phone]
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France OperaƟons
Clos D’Asseville
BP4
95450 Us Par Vigny
France
33-1-30-27-9500
FAX: [phone]
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.
For The Long Haul, The Future of Fastening
Technology, The Future of Assembly Technology,
The Future of Tooling Technology, and Tools
of ProducƟvity are service marks of Huck
InternaƟonal. Huck provides technical assistance
regarding the use and applicaƟon of Huck
fasteners and tooling.
NOTICE: The informaƟon contained in this
publicaƟon is only for general guidance with
regard to properƟes of the products shown
and/or the means for selecƟng such products,
and is not intended to create any warranty,
express, implied, or statutory; all warranƟes
are contained only in Huck’s wriƩen quotaƟons,
acknowledgments, and/or purchase orders. It
is recommended that the user secure specific,
up-to-date data and informaƟon regarding each
applicaƟon and/or use of such products.
HWB898 1003-5M
© 2015 Alcoa Fastening Systems & Rings
1 Corporate Drive, Kingston, NY 12401 • Tel: [phone] • Fax: [phone] • www.alcoafasteningsystems.com
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ISO 14001:2004
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®