Alcoa 2503 series User manual

08-23-2005
HK840
INSTRUCTION MANUAL
2503 & A2503 SERIES
HYDRAULIC INSTALLATION TOOLS

2503 Series Tooling Alcoa Fastening Systems
ii
EU Declaration of Conformity
Manufacturer:
Alcoa Fastening Systems, Commercial Products Division, 1 Corporate Drive, Kingston, NY,
12401, USA
Description of Machinery:
Model numbers 2503 series 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 the
above Directive(s) and Standard(s).
Signature: ___________________________________
Full Name: Henk Rosier
Position: Engineering Manager
Installation Systems Division
Place: Kingston, New York, USA
Date: June, 2005
Sound Levels
Models: 2503 Series
To calculate equivalent noise level for other quantities of
fasteners in an eight hour period, use the formula:
Leq = SEL + 10 log (n/28,800)
where n= number of fasteners in eight hours.
Vibration Levels
Models: 2503 Series
For an eight hour work day, installing 1,000 typical Huck
fasteners will result in an equivalent weighted RMS
vibration level A(8) of:
2.65 m/s2
To calculate equivalent vibration level for other quantities of
fasteners in an eight hour period, use the formula:
Equivalent Vibration Level, A8 (m/s2) = (n/480) x 15.25
where n= number of fasteners in eight hours,
and 15.25(m/s2)= Aeq for 60 seconds.
Test data to support the above information is on file at Alcoa Fastening Systems, Commercial Products Division, Kingston
Operations, Kingston, NY, USA. Vibration measurements are frequency weighted in accordance with ISO 8041 (1990).
SEL
dB (A)
Peak Value
dB (C)
Leq
dB (A)
92 116 77.4
Leq reflects the
equivalent noise
level result of
installing 1,000
typical Huck
fasteners for an
eight hour work day.

2503 Series Tooling Alcoa Fastening Systems
iii
EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
DESCRIPTION AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CHECKING AND ADJUSTING PRESSURES . . . . . . . . . . . . . . . . . . . . . . . .5
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SPARE PARTS AND SERVICE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14
HYDRAULIC QUICK DISCONNECT COUPLINGS . . . . . . . . . . . . . . . . . . .15
ELECTRIC/AIR CONTROLS AND HYDRAULIC HOSES . . . . . . . . . . . . . .16
SPECIFICATIONS FOR STANDARD PARTS . . . . . . . . . . . . . . . . . . . . . . . .17
PISTON DISASSEMBLY/ASSEMBLY TOOL . . . . . . . . . . . . . . . . . . . . .18-20
FASTENER SELECTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
TOOL ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-23
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
CONTENTS

2503 Series Tooling Alcoa Fastening Systems
iv
SAFETY
This instruction manual must be read with particular
attention to the following safety guide lines, by
any person servicing or operating this tool.
1. Safety Glossary
WARNINGS - Must be understood
to avoid severe personal injury.
CAUTIONS - show conditions that will
damage equipment and or structure.
Notes - are reminders of required
procedures.
Bold, Italic type and underlining -
emphasizes a specific instruction.
2. Huck equipment must be maintained in a safe
working condition at all times and inspected on a
regular basis for damage or wear. Any repair
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 Warning
and Caution stickers/labels supplied with
equipment before connecting equipment to any
primary power supply. As applicable, each of the
sections in this manual have specific safety and
other information.
4. See MSDS Specifications before servicing the
tool. MSDS Specifications are available from
you Huck representative or on-line at
www.huck.com. Click on Installation Systems
Division.
5. When repairing or operating Huck installation
equipment, always wear approved eye
protection. Where applicable, refer to ANSI
Z87.1 - 1989
6. Disconnect primary power source before doing
maintenance on Huck equipment.
7. If any equipment shows signs of damage, wear,
or leakage, do not connect it to the primary
power supply.
8. Make sure proper power source is used at all
times.
9. Never remove any safety guards or pintail
deflector.
10. Never install a fastener in free air. Personal
injury from fastener ejecting may occur.
11. When using an offset nose always clear spent
pintail out of nose assembly before installing the
next fastener.
12. If there is a pinch point between trigger and
work piece use remote trigger. (Remote
triggers are available for all tooling).
13. Do not abuse tool by dropping or using it as a
hammer. Never use hydraulic or air lines as a
handle. 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.
14. Never place hands between nose assembly and
work piece.
15. Tools with ejector rods should never be cycled
with out nose assembly installed.
16. When two piece lock bolts are being used
always make sure the collar orientation is
correct. See fastener data sheet of correct
positioning.
!
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.