Alcoa 7142 User manual

February 4, 2014
HK606
INSTRUCTION MANUAL
M
MODELS ODELS 7142 & 8142 7142 & 8142
HYDRAULIC INSTALLATION TOOLS
7142
7142
7142-20
7142-20
8142
8142

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
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7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
3
C
CONTENTS ONTENTS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sticker Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . 9
Components Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
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I. GENERAL SAFETY RULES:
1. A half hour long hands-on training session with qualified personnel is recom-
mended 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 proce-
dures.
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. Read MSDS Specifications before servicing the tool. 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 down-
time, 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 with out 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 nor-
mal 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.
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 maintain-
ing a secure footing and avoid awkward or off balanced postures.
3. The operator should change posture during extended tasks to help avoid discom-
fort 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 recommend-
ed. 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 haz-
ards such as electricity or other utility lines.
3. The assembly power tool is not intended for use in potentially explosive environ-
ments.
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 mate-
rials 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 work-
ing 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.
X. HYDRAULIC TOOL SAFETY INSTRUCTIONS:
1. Do not exceed maximum pressure setting stated on tool.
2. Carry out a daily check for damaged or worn hoses or hydraulic connections and
replace if necessary.
3. Use only clean oil and filling equipment.
4. 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.
5. Ensure that couplings are clan and correctly engaged before operation.
6. Do not inspect or clean the tool while the hydraulic power source is connected.
Accidental engagement of the tool can cause serious injury.
7. Be sure all hose connections are tight.
8. Wipe all couplers clean before connecting. Failure to do so can result in damage
to the quick couplers and cause overheating.
GLOSSARY OF TERMS AND SYMBOLS:
- Product complies with requirements set forth by the rele-
vant European directives.
-READ MANUAL prior to using this equipment.
-EYE PROTECTION IS REQUIRED while using this equip-
ment.
-HEARING PROTECTION IS REQUIRED while using this
equipment.
Notes: are reminders of required procedures.
Bold, Italic type and underlining: emphasizes a specific instruction.
S
SAFETY AFETY I INSTRUCTIONS NSTRUCTIONS
CAUTIONS: show conditions that will
damage equipment and or structure.
WARNINGS: Must be understood to avoid
severe personal injury.

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
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Huck Models 7142 and 8142 Hydraulic Installation Tools install HUCKBOLT® fasteners. These inline tools are lightweight, com-
pact, and designed to install fasteners in limited clearance areas.
The tools operate on 7,400 psi (510 bar) PULL pressure and 3,200 psi (220 bar) RETURN pressure, as supplied by HUCK
Powerig® Hydraulic Unit. They are electric-triggered tools designed for use with HUCK Powerig Models 913, 918, and 940, or
equivalent. The nose assembly is part of the tool. The 7142 installs 3/4 inch (-24) and the 8142 installs 7/8 inch (-28) HUCK-
BOLTS.
Basic subassemblies are a Cylinder/Cap Assembly, Piston Anvil Assembly, Collet/Jaws Assembly, and an Unloading Valve to
relieve hydraulic pressure at end of PULL stroke. Tool is complete with hydraulic hoses, couplings, and electric trigger control
assembly.
S
SPECIFICATIONS PECIFICATIONS
D
DESCRIPTION ESCRIPTION
ØA
E
ØB
C
D
ØF ØG
E
C
D
ØA ØB ØF ØG
7142
7142-20
7142
7142-20 8142
8142
POWER SOURCE: Huck POWERIG Hydraulic Unit
HOSE KITS: Use only genuine HUCK Hose Kits rated @
10,000 psi working pressure.
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 para-
graph (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 tempera-
tures to which it will be exposed."
MAX OPERATING TEMP: 125° F (51.7° C)
MAX FLOW RATE: 2 gpm (7.6 l/m)
WEIGHT:
7142 & 7142-20: 14.25 lbs (6.46 kg)
8142: 18 lbs (8.16 kg)
STROKE:
ALL MODELS: 1.375 in. (3.49 cm)
MAX INLET (PULL) PRESSURE:
7,400 psi (579 bar)
MAX RETURN PRESSURE:
3,200 psi (220.6 bar)
PULL CAPACITY:
114,300 lbs (508.4 kN) @ 8,400 psi (579 bar)
TOOL A B C D E F G
7142 4.43 (11.25) 1.75 (4.44) 4.50 (11.43) 4.26 (10.82) 3.24 (8.23) 2.75 (6.98) 1.50 (3.81)
7142-20 4.43 (11.25) 1.88 (4.76) 4.50 (11.43) 4.26 (10.82) 3.24 (8.23) 2.75 (6.98) 1.50 (3.81)
8142 5.20 (13.20) 2.12 (5.38) 4.32 (10.97) 4.08 (10.36) 3.26 (8.28) 3.00 (7.62) 2.15 (5.46)
FIGURE 1
inches (cm)

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
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Hydraulic hoses and trigger control cord are connected to Powerig Hydraulic Unit. The trigger controls PULL and
RETURN strokes of the tool. Trigger is depressed and hydraulic pressure is directed to the PULL side of the anvil/pis-
ton and it moves forward. Fastener installation begins. When the fastener installation is completed, trigger is
released. Hydraulic pressure is directed to the RETURN side if anvil/piston, moving piston rearward. Nose assembly,
with tool, is pushed off installed fastener. At end of PULL stroke piston uncovers a flat on the unloading valve.
When this occurs, PULL pressure is allowed to flow back to the reservoir in Powerig Hydraulic Unit.
P
PRINCIPLE RINCIPLE OF OF O OPERATION PERATION
Note: Where a part number (P/N) is given, Huck sells
that part.
CONNECTING THE TOOL
Remove shipping caps from ends of pipe plug fittings.
Coat pipe plug threads, hose fitting threads, and quick
connect fittings with Threadmate™, which is available
from Huck in a 4oz. tube as part number 508517.
Threadmate is a registered trademark of Parker Intangibles
LLC
1. Use Huck POWERIG Hydraulic Unit, or equivalent, that
has been prepared for operation per instruction man-
ual. 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 trigger
control system from hydraulic unit.
3. Connect PULL pressure hose, with coupler nipple, into
port “P” of tool. Connect RETURN pressure hose, with
coupler body, into port “R” of tool. Check trigger
assembly for apparent damage or wear.
4. If required, adjust position of trigger assembly on
return pressure hose. Connect trigger control system
to hydraulic unit.
5. Connect hydraulic unit to power supply. Turn
hydraulic unit to ON. Depress trigger a few times to
cycle tool and to circulate hydraulic fluid. Observe
action of Tool and check for leaks and operation of
nose assembly.
6. Disconnect tool from power supply.
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 equipment,
always wear approved eye and ear protection.
Be sure there is adequate clearance for the
operator’s hands before proceeding.
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.
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 pres-
sure for both PULL and RETURN, AND ARE
NOT EQUIPPED WITH RELIEF VALVES ARE
SPECIFICALLY NOT RECOMMENDED AND MAY
BE DANGEROUS.
P
PREPARATION REPARATION FOR FOR U USE SE
Read all WARNINGS and CAUTIONS before operating or performing maintenance on HUCK equipment.
CAUTIONS:
Do not abuse the tool by dropping it, using it
as a hammer, or otherwise causing unneces-
sary wear and tear.
Reasonable care of installation tools by oper-
ators is an important factor in maintaining
tool efficiency and reducing down time.
WARNING: Correct PULL and RETURN pres-
sures are required for operator’s safety and
for Installation TooI’s function. Pressure
Gauge T-124833CE is available 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 con-
necting Tool’s switch control cord to unit. If
not connected in this order and disconnected
in the reverse 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.

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
7
O
OPERATING PERATING I INSTRUCTIONS NSTRUCTIONS
GENERAL
Operators should receive training from qualified per-
sonnel.
Do not bend tool to free if stuck.
Tool should only be used to install fasteners. NEVER use
as a jack/spreader or hammer.
HUCKBOLT® FASTENER INSTALLATION:
•Length of tool increases during fastener installation.
Allow adequate tool and anvil clearance before installing
fasteners.
•Before starting, hold trigger down for approximately one
minute to be sure tool is filled with air-free hydraulic
fluid.
•Check pin for correct grip. Place pin in work hole.
•Place collar over pin with collar chamfer away from
tool (against workpiece). See WARNINGS. If collar has
only one tapered end, that end should be outward
toward tool.
•Hold pin in hole. Push tool onto pin protruding from col-
lar until anvil touches collar.
•Move hands away from pin and structure. Keep hands
away from front of tool during operation. Tool anvil
advances forward.
•Hold tool at right angle (90 degrees) to workpiece. Press
and hold trigger down until collar is swaged and pintail
breaks.
•If pintail does not break off, operate trigger to recycle
tool until pintail breaks and tool is released from fastener.
•Release trigger. Tool returns to starting position.
•Tool is ready for next installation cycle.
Before proceeding with operation, read and understand completely PREPARATION FOR USE,
OPERATING INSTRUCTIONS, and all WARNINGS and CAUTIONS.
WARNING: To avoid severe personal injury:
Wear approved eye and ear protection. Be sure
of adequate clearance for Operator’s hands
before proceeding with fastener installation.
WARNING: Do not pull on a pin without plac-
ing fastener/collar in a workpiece with collar
chamfer away from tool (against workpiece).
These conditions cause pin to eject with great
velocity and force when the pintail breaks off
or teeth / grooves strip. This may cause
severe personal injury. CAUTIONS:
· Tool must be tilted down to allow broken-off
pintail to drop out.
· Avoid binding or prying of hoses. Do not pull
or carry tool by holding the hoses.
CAUTION: Remove excess gap from between
the sheets. This permits enough pintail to
emerge from collar for ALL jaw teeth to engage
with pintail. If ALL teeth do not engage proper-
ly, jaws will be damaged.
H
HYDRAULIC YDRAULIC C COUPLINGS OUPLINGS
FIGURE 2
S
STICKER TICKER L LOCATIONS OCATIONS
The 7142 and 8142 series tools come labeled
with important stickers on the outside of the
cylinder which contain safety and pressure
settings information. It is necessary that
these stickers remain on the tools and are
easily read. If stickers become damaged or
worn, or if they have been removed from the
tool, they must be replaced.
7400
58000
3200
22100
590189-2
CAUTION SƟcker
590517
Trademark / Year
of Manufacture
SƟcker
FIGURE 3

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
8
SYSTEM INSPECTION
1A clean, well-lit area should be available for servicing
the tool.
2Inspect tool daily. Check hoses, fittings and disconnects
for leaks or damage.
3Special care must be taken to prevent contamination of
pneumatic and hydraulic systems.
4Proper hand tools and soft materials to protect tools
must be available. Use only standard hand tools, brass
drift and wood block. Vise with soft jaws should be
available. Unsuitable hand tools will cause installation
tool damage.
5Apply continuous strong pressure to disassemble a
component. An arbor press provides steady pressure to
press a component into or out of an assembly.
6Never continue to force a component if it “hangs-up”
due to misalignment. Reverse the procedure to correct
misalignment and start over.
7Assemble Release and Ejector Kit with Loctite* adhesive
sealant. (part no. 503657).
8All parts must be handled carefully and examined for
damage and/or wear.
9Components should be disassembled and assembled in
a straight line without bending, cocking or undue force.
10 Disassembly and assembly procedures in this manual
should be followed. If Huck recommended procedures
are not followed, the tool may be damaged.
STANDARD SEALANTS, LUBRICANTS
Coat pipe plug threads, hose fitting threads, and quick con-
nect fittings with Threadmate™, which is available from
Huck in a 4oz. tube as part number 508517.
Smear LUBRIPLATE®13OAA*, or equivalent lubricant, on O-
Rings and mating surfaces to aid assembly and to prevent
damage to O-Rings. (LUBRIPLATE 13O-AA is available in a
tube as Huck P/N 502723.)
* Loctite is a registered trademark of Henkel Corporation, U.S.A.
* Threadmate is a registered trademark of Parker Intangibles LLC
* TEFLON is a registered trademark of DuPont Corp.
* LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.
PREVENTIVE MAINTENANCE
Operating efficiency of the tool is directly related to per-
formance of complete system, including tool/nose assem-
bly, hydraulic hoses, control 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 troubles.
•Inspect tool daily for damage or wear.
•Verify that hoses, fittings, and trigger connections are
secure.
•Inspect hydraulic hoses for signs of leaks or damage.
Replace if required.
•Inspect tool, hoses, and POWERIG Hydraulic Unit dur-
ing operation to detect abnormal heating, leaks, or
vibration.
•Check tool for leaks before each use.
POWERIG HYDRAULIC UNIT MAINTENANCE
Maintenance and repair instructions are in applicable POW-
ERIG Hydraulic Unit Instruction Manual.
TOOL/NOSE MAINTENANCE AND PRECAUTIONS
Whenever disassembled, and also at regular intervals
(depending on severity and length of use), replace all O-
rings and back-up rings. Spare Parts Kits should be kept on
hand. Inspect cylinder bore, piston and rod/extension, and
unloading valve for scored surfaces, excessive wear or dam-
age. Replace parts as necessary. Clean all parts in mineral
spirits or isopropyl alcohol only. Do not let jaws come in
contact with other solvents under any circumstances.
Also, do not let jaws soak. Dry the jaws immediately after
cleaning. Dry other parts before assembling. Use a sharp
pointed “pick” to remove imbedded particles from the pull
grooves of the jaws.
M
MAINTENANCE AINTENANCE
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
Dump Valve failure in Tool and in POW-
ERIG® Hydraulic Unit’s valves.
- Always check tool assembly drawing for
the proper direction of the flats on the
Dump Valve.
CAUTION: Always replace seals, wipers, and
back-up rings when tool is disassembled for
any reason.
CAUTION: Do not use TEFLON®tape on
pipe threads. Pipe threads may cause tape
to shred resulting in tool malfunction.
(Threadmate™ is available from Huck in a
4oz. tube as part number 508517.)

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
9
D
DISASSEMBLY ISASSEMBLY
The following procedure is for disassembly of Tool. Remove
only those parts necessary. The retainer is removed for jaw
maintenance; the collet and release assembly are removed
to service release/ejector assembly. Check and replace dam-
aged/worn components. Always replace O-rings, wipers,
and back-up rings when disassembling tool.
1. Disconnect electric trigger control cord, then uncouple
Hydraulic Hoses.
2. Unscrew coupling nipple and coupling body. Drain
hydraulic hoses into a container, and discard fluid.
3. To remove retainer, thread out of collet. Pull out follower
with O-rings; remove jaws.
4. Remove cap screw and lockwasher that holds lock cap.
5. Using a sliding pin spanner, remove lock cap.
6. 7142, 7142-20: Remove cap screw from split lock nut.
Unscrew from collet.
8142: Remove setscrew from collet lock ring. Unscrew
ring from collet.
7. Using an arbor press and suitable stand-off, press piston
anvil and front glandout of cylinder.
8. Remove dump valve from piston anvil.
9. Normally, ejector and release cannot be disassembled by
unscrewing. Hold collet in a toolmaker’s vise, and using a
hack saw, band saw, or abrasive cutting wheel, cut at a
point between flange of ejector and end of collet.
10.Loosen two screws on cord grip. Loosen cup-point
setscrew. Pull switch from housing.
11.Loosen two screws at rear of switch to remove switch
from electrical cord. Remove two #6-32 socket setscrews
to dismantle switch for cleaning. Remove cord grip from
housing.
12.Disconnect electrical connector to rewire or replace.
A
ASSEMBLY SSEMBLY
Clean all tool components with mineral spirits or equivalent,
and inspect for wear or damage. Replace as required.Always
replace all seals on/in disassembled components. Use O-
rings and back-up rings supplied in SERVICE PARTS KIT,
7142KIT or 8142KIT. Smear LUBRIPLATE 130AA, or equiva-
lent, on O-rings, back-up rings and mating components for
ease of assembly. Assemble Tool taking care not to damage
either O-rings or back-up rings.
1. Read M MAINTENANCE
AINTENANCE - S - SYSTEM YSTEM I INSPECTION NSPECTION, I , INSTRUCTION NSTRUCTION 7 7.
Apply Threadmate™ (available from Huck in a 4oz. tube
as part number 508517) to Release. Follow instructions
for cleaning and Threadmate application. Assemble
Release to Collet and Ejector.
2. Press collet into cylinder; press anvil down over collet.
3. With flats toward the front of the tool, as shown on the
components drawing, slide Dump Valve into Anvil.
4. Press cylinder gland into cylinder.
5. Install lock cap retainer screw and lockwasher.
6. 7142, 7142-20: Thread split lock ring onto collet. Tighten
lock ring against cylinder. Install cap screw.
8142: Thread split lock ring onto collet. Tighten lock ring
against cylinder. Install setscrew.
7. Place jaws in collet. Push follower and O-ring assembly
into collet. Use flat bar in slots to tighten gland/retainer
into collet.
8. If hydraulic hoses have been removed, tighten hoses into
cylinder.
9. Screw male coupler onto PULL pressure hose (from “P”
port) and female coupler onto RETURN pressure hose.
10. If necessary, rewire and assemble electrical connector.
Screw cord grip into housing.
11. Assemble switch, installing two #6 setscrews. Attach cord
using two screws at rear of switch.
12. Push switch into housing and tighten cup point setscrew
to hold switch. Tighten two screws on cord grip.
13. See WARNING in D DISASSEMBLY ISASSEMBLY and reverse the given
procedure; i.e. CONNECT HOSES FIRST, and then con-
nect electrical control cord before testing tool on
hydraulic unit. Proceed to P PREPARATION REPARATION FOR FOR U USE SE section.
WARNING: Be sure to disconnect electrical
control trigger system from Powerig®
Hydraulic Unit BEFORE disconnecting
hydraulic hoses from unit. If not disconnect-
ed in this order before every maintenance or
cleaning, 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.
(Threadmate™ is available from Huck in a
4oz. tube as part number 508517.)
WARNING: Do not omit any seals when
assembling tool. Leaks will result, and per-
sonal injury may occur.
CAUTION: Always use proper unloading
(dump) valve, and always make sure the
flats of the valve are oriented in the tool as
shown inindividual components drawings
on the next three pages of this manual.
WARNING: Tool must be fully assembled
with all components included prior to testing
and/or operation.

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
10
122325 Follower
Tool is also shipped with
pass-through Follower 122325-1
128228 Retainer
500790 O-Ring
500846 O-Ring (9)
500125 Screw
503872 O-Ring
503963 Back-up Ring
104926 Chuck Jaws 503411
Back-up
Ring
503880 O-Ring
503411 Back-up Ring
116981 Split Locking Nut
Cylinder
502847 Lockwasher
505189 Screw
505013 O-Ring
505015 Back-up Ring
121211 Cylinder Gland
504600 O-Ring
501121 Back-up Ring
116978
Unloading
Valve
111334 Lock Cap
503876 O-Ring
502841 Back-up Ring
111331 Piston Anvil
122297
Release and Ejector Kit
(parts not sold separately)
Alternate Collet stack conguration
using Collet Stack Kit 123100
508230 Spring
507037 Washer
500846 O-Ring
507037 Washer
500846 O-Ring (2)
111332 Collet
See Figure 7for Trigger, Hose, and
Fiƫng part numbers.
7142 C
7142 COMPONENTS OMPONENTS D DRAWING RAWING
FIGURE 4

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
11
122325 Follower
Tool is also shipped with
pass-through Follower 122325-1
128228 Retainer
500790 O-Ring
500846 O-Ring (9)
500125 Screw
503872 O-Ring
503963 Back-up Ring
128243 Chuck Jaws 503411
Back-up
Ring
503880 O-Ring
503411 Back-up Ring
116981 Split Locking Nut
Cylinder
502847 Lockwasher
505189 Screw
505013 O-Ring
505015 Back-up Ring
121211 Cylinder Gland
504600 O-Ring
501121 Back-up Ring
116978
Unloading
Valve
111334 Lock Cap
503876 O-Ring
502841 Back-up Ring
128244 Piston Anvil
128320
Release and Ejector Kit
(parts not sold separately)
Alternate Collet stack conguration
using Collet Stack Kit 123100
508230 Spring
507037 Washer
500846 O-Ring
507037 Washer
500846 O-Ring (2)
111332 Collet
See Figure 7for Trigger, Hose, and
Fiƫng part numbers.
7142-20 C
7142-20 COMPONENTS OMPONENTS D DRAWING RAWING
FIGURE 5

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
12
118917 Follower
Tool is also shipped with
pass-through Follower
118917-1
128230 Retainer
500796 O-Ring
500852 O-Ring (8)
505017 Setscrew
503876 O-Ring
502841 Back-up Ring
104927 Chuck Jaws 503585
Back-up
Ring
503885 O-Ring
503585 Back-up Ring
111705 Lock Ring Collet
111699 Cylinder
502847 Lockwasher
500100 Screw
504646 O-Ring
501167 Back-up Ring
118916 Cylinder Gland
504634 O-Ring
501155 Back-up Ring
116978
Unloading
Valve
118914 Lock Cap
503879 O-Ring
502938 Back-up Ring
111708 Piston Anvil
121242
Release & Ejector Kit
(parts not sold separately)
111702 Collet
See Figure 7for Trigger, Hose, and
Fiƫng part numbers.
8142 C
8142 COMPONENTS OMPONENTS D DRAWING RAWING
FIGURE 6

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
13
123749-5 Hose (2) 110438 Male Coupler
110439 Female Coupler
123381 Trigger/
Cord Assembly
123380 Trigger/Hose
Clamp Assembly
See Top View
See Side View
Top View
Side View
Partial View of Trigger/Hose & Clamp Assembly
7142
7142 AND AND 8142 T 8142 TRIGGER RIGGER, H , HOSE OSE, , AND AND F FITTINGS ITTINGS
FIGURE 7

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
14
1. Tool fails to operate when trigger is depressed.
a. Inoperative Powerig® unit. See unit instruction manual.
b. Loose air or electric connections.
c. Damaged trigger assembly.
d. Loose or faulty hydraulic hose couplings.
e. Unloading valve not installed in Tool.
2. Tool operates in reverse.
a. Reversed hydraulic hose connections between Powerig and
Tool.
3. Tool leaks hydraulic fluid.
a. Defective Tool O-rings or loose hose connections at Tool.
4. Hydraulic couplers leak fluid.
a. Damaged or worn O-rings in coupler body. See H HYDRAULIC YDRAULIC
C
COUPLINGS OUPLINGS on page 7.
5. Hydraulic fluid overheats.
a. Hydraulic unit not operating properIy.
b. Unloading valve installed incorrectly.
c. POWERIG unit running in reverse (918: 918-5) See unit man-
ual.
6. 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. Unloading valve installed incorrectly.
d. Excessive wear on sliding surfaces of Tool parts.
e. Excessive wear of unloading valve in Tool.
7. Pull grooves on fastener pintail stripped during PULL stroke.
a. Operator not sliding anvil completely onto fastener pintail.
b. Incorrect fastener grip.
c. Worn or damaged jaw segments.
d. Metal particles in pull grooves of jaw segments.
e. Excessive sheet gap.
8. Collar of HUCKBOLT® fastener not completely swaged.
a. Improper Tool operation. See Trouble 6.
b. Scored anvil.
9. Jaw segments do not maintain proper position in collet.
a. Improper operation of follower. Check number of follower
O-Rings
10.Tool “hangs-up” on swaged collar of HUCKBOLT Fastener.
a. Improper Tool operation. See Trouble 6.
b. RETURN pressure too low.
11.Pintail of fastener fails to break.
a. Improper Tool operation. See Trouble 6.
b. Pull grooves on fastener stripped. See Trouble 7.
c. PULL pressure too low.
d. Worn unloading valve.
T
TROUBLESHOOTING ROUBLESHOOTING
Always check the simplest possible cause of a malfunction first.
For example, a loose or disconnected trigger line. Then proceed
logically, eliminating each possible cause until the defective
part is located. Where possible, substitute known good parts for
suspected defective parts. Use this section as an aid for locating
and correcting trouble.
K
KITS ITS AND AND A ACCESSORIES CCESSORIES
Service Parts Kit
Includes all perishible seals, O-rings and Back-up rings.
A spare Service Parts Kit should be kept on hand at all
times.
7142KIT (7142 and 7142-20)
8142KIT (8142)
7142 Collet & Release Assembly 112135 includes:
111332 Collet
122297 Release & Ejector Assy (parts not sold separately)
7142-20 Collet & Release Assembly 128322 includes:
111332 Collet
128320 Release & Ejector Assy (parts not sold separately)
8142 Collet & Release Assembly 111869 includes:
111702 Collet
121242 Release & Ejector Assy (parts not sold separately)
Release and Ejector Tool 124751
for -20 and -24 Nose Assemblies and Tools
This assembly tool is available for disassembling and
assembling -20 (5/8) and -24 (3/4) release and ejector
assemblies in the 99-5000 series. The tool is also used
with 582/682, 6304 through 8304, and 7142/8142 tools.
The assembly tool’s locking taper locks into the release’s
taper. This prevents the release fom turning while the
ejector is unscrewed. Use an open
end wrench.
1. Lock assembly tool in vise
as shown.
2. Place collet assembly over
taper Using a soft mallet (or
hammer), tap assembly
firmly onto taper to ensure
that tapers are locked
together.
3. Using an open end wrench
on ejector flats, unscrew
ejector from release.
4. Lift collet off release. With
soft mallet tap release from
assembly tool.
5. Assemble in reverse order.

7142 & 8142 SERIES HYDRAULIC INSTALLATION TOOLS (HK606) Alcoa Fastening Systems
15
L
LIMITED
IMITED W
WARRANTIES
ARRANTIES
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 man-
ufactured 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 manufac-
tured 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 WAR-
RANTIES 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 MANUFAC-
TURED PRODUCTS FOR ANY PARTICULAR PUR-
POSE AND HUCK SHALL NOT BE LIABLE FOR
ANY LOSS OR DAMAGE, DIRECTLY OR INDI-
RECTLY, 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 DAM-
AGES.
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, nonstan-
dard or custom products found to be defective in
specifications, workmanship and materials not other-
wise 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 MANU-
FACTURED 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 CONDI-
TION, DESIGN, OPERATION, MERCHANTABILITY
OR FITNESS FOR USE OF ANY TOOL, PART(S),
OR OTHER ITEMS THEREOF NOT MANUFAC-
TURED BY HUCK. HUCK SHALL NOT BE LIABLE
FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDI-
RECTLY, ARISING FROM THE USE OF SUCH
TOOLING, PART(S) OR OTHER ITEMS OR
BREACH OF WARRANTY OR FOR ANY CLAIM
FOR INCIDENTAL OR CONSEQUENTIAL DAM-
AGES.
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 result-
ing from delays or nonfulfillment 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 discontin-
ue 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 con-
tact 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: 520‐748‐2142
Alcoa Fastening Systems
Aerospace Products
Carson Operations
PO Box 5268
900 Watson Center Rd.
Carson, CA 90749
800‐421‐1459
310‐830‐8200
FAX: 310‐830‐1436
Alcoa Fastening Systems
Industrial Products
Waco Operations
PO Box 8117
8001 Imperial Drive
Waco, TX 76714‐8117
800‐388‐4825
254‐776‐2000
FAX: 254‐751‐5259
Alcoa Fastening Systems
Industrial Products
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
800‐278‐4825
845‐331‐7300
FAX: 845‐334‐7333
Alcoa Fastening Systems
Industrial Products
Latin America Operations
Avenida Parque Lira. 79‐402
Tacubaya Mexico, D.F.
C.P. 11850
FAX: 525‐515‐1776
TELEX: 1173530 LUKSME
Far East
Alcoa Fastening Systems
Industrial Products
Australia Operations
14 Viewtech Place
Rowville, Victoria
Australia 3178
03‐764‐5500
Toll Free: 008‐335‐030
FAX: 03‐764‐5510
Europe
Alcoa Fastening Systems
Industrial Products
United Kingdom Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952‐290011
FAX: 0952‐290459
Alcoa Fastening Systems
Aerospace Products
France Operations
Clos D’Asseville
BP4
95450 Us Par Vigny
France
33‐1‐30‐27‐9500
FAX: 33‐1‐34‐66‐0600
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
provide 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 fasten‐
ers and tooling.
NOTICE: The information contained in this publi‐
cation 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 recommend‐
ed 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: 800‐431‐3091 • Fax: 845‐334‐7333 • www.alcoafasteningsystems.com
Certified to
ISO 14001:2004
Industrial
Products
Certified to
ISO 9001:2008
Industrial
Products
One Great ConnectionSM
Alcoa Fastening Systems world-wide locations:
For the Long Haul™
®