H.K. Porter 8690 Series User manual

Service Manual
P18690
09/28/2009
8690 Series
Ratchet Type Cutters
For additional product information visit our website at
http://www.coopertools.com
8690TN
8690FH
8690FSK
8690CK
8690CS

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P18690
09/28/2009
HH..KK.. PPoorrtteerr®
8690 Series Disassembly and Assembly
The following disassembly and assembly procedures
apply to all models except where noted.
Disassembly:
1. Secure the tool in a vise by the right handle (handle
without the ratchet) with the left handle parallel to the
floor and the head pointing away from you.
2. TN model: Cut the rubber handle grip (P0380 ) from
the handle. Be careful not to damage the plastic sleeve.
3. FH, FSK, CK, and CS models: In the end of the left
handle (the ratcheting handle), insert a hook type tool
through the access hole in the end of the handle grip,
hook the spring, pull the spring slightly towards you,
twist 90 degrees and unhook the spring (P8678FS)
from the pin. Note: removal of the handle grip is no
longer required as a result of the added access hole to
the new grip.
3a. TN model: Unhook the spring extension (P8679TN)
from the pin on the ratchet handle using a hook type
tool.
4. Loosen nut (T3171) from bolt (P8635FS) using 7/16”
wrenches.
5. Remove the bolt and snubber (P8654FS).
6. Remove the tool from the vise.
7. Unhook the two closing springs (P8658FH).
8. Remove the closing spring bolt (P8634FS), nut
(T3171) and snubber (P8654FS).
9. Remove the cutterhead from the handles using 9/16”
wrenches. Important: Note the difference in length
between the two sets of bolts.
10. Remove the right handle assembly, with the chain
and spring still attached, from the left handle.
11. Remove the nut (P2666K) from the sprocket pivot
bolt (P8692FS) using a 9/16” wrench.
12. Remove the sprocket pivot bolt (P8692FS).
13. Remove the two side plates (P8621FS), sprocket
(P8624FS), bushing (P8642FS), detent pawl
(P8637FS), and spring (P8677FS).
14. Remove the two crank plate bushings (P8646FS).
15. Clean all parts thoroughly with solvent.
Assembly:
1. Assemble the pivot bolt (P8692FS) to one of the side
plates (P8621FS). atch the flat on the bolt with the flat
in the plate hole. Lay this assembly on the bench with
the bolt head down and the notched edge of the plate
nearest to you. See Illustration 1.
2. Apply a light film of grease to the shank of the pivot
bolt.
3. Slide the sprocket (P8624FS) onto the pivot bolt.
4. Apply grease to the detent spacer bushing
(P8642FS) and slide into the detent pawl. Place the
detent spring (P8677FS) onto the pin making sure the
spring ends have not been bent out of shape. The cross
arm of the spring goes under the flat side of the narrow
shaped point of the detent pawl. See Illustration 2.
5. Assemble one end of the detent spacer bushing
(P8642FS) into the hole on the side plate (P8621FS)
and engage the rounded end of the pawl with the
sprocket (P8624FS). See Illustration 3.
Illustration 1
Illustration 2
Illustration 3

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P18690
09/28/2009
HH..KK.. PPoorrtteerr®
8690 Series Disassembly and Assembly
6. atch up the second side plate (P8621FS) with the
first and place it over the detent spacer and pivot bolt.
Do not insert the spring ends into the plates at this
point. See Illustration 4.
7. Hold the left handle (P8606FH or P8606TN) in a vise
with the drive pawl facing up and the handle pointing to
your left. Pull the drive pawl up, moving counter
clockwise, and insert a 1/8” rod or nail through the small
holes in the plates near the drive pawl to hold it in a
horizontal position. See Illustration 5.
8. Place a small amount of grease on each of the two
crank plate bushings (P8646FS) at the shoulder and
insert them into the pivot bolt hole with the shoulders on
the inside. The grease will hold them in position.
9. Hold the side plate assembly firmly with the notched
edges of the plate facing down. While holding tightly
between your fingers, remove the pivot bolt.
10. Carefully insert the plate assembly into the left
handle between the bushings (P8646FS). Align the
pivot bolt holes and slide the pivot bolt into position from
the far side of the handle. See Illustration 6.
11. Assemble spacer (P8644FS) and nut (P2666K) to
the pivot bolt and tighten up snug. Note: This assembly
must pivot freely.
12. With a small hook tool, reach up from the bottom of
the assembly, between the plates, and hook the ends
of the detent spring into their respective holes. See
Illustration 7. ake sure the spring loops are not
caught between the pin and side plate.
13. Remove the 1/8” pin from under the pawl and
engage the drive pawl with the sprocket (P8624FS).
14. Remove the handle from the vise.
15. Hook the longer loop on the chain spring (P8678FS)
onto the free end of the chain (P8653FS). Lay the left
and right handles on the bench with the drive pawl on
the left handle and the chain on the right handle facing
each other. Feed the spring on the chain over the
sprocket and into the left handle. See Illustration 8.
Illustration 4
Illustration 5
Illustration 6
Illustration 7

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P18690
09/28/2009
HH..KK.. PPoorrtteerr®
8690 Series Disassembly and Assembly
16. With the handles remaining in this position,
assemble the cutting head to the left handle. The thicker
washer (P8645FS) goes on the bottom between the
handle and the jaw. The thinner washer (P8644FS)
goes on top. See Illustration 9. Use the longer bolt
(P8628FS) and nut (P2666K) and tighten securely.
17. Assemble the other side of the head to the right
handle using bolts (P0135SK) and nut (P2666K).
Tighten securely.
18. Hook the open end of the closing spring (P8658FH)
into the holes in the handle (P8606FH or P8606TN).
ake sure the closed loops are against the side plates
(P8621FS).
19. Insert bolt (P8634FS) through the closed loop on
one of the springs (P8658FH) and insert through the
1/4” hole in the side plate (P8621FS). At the same time
assemble the snubber (P8654FS) and slide the bolt
through the snubber.
20. Assemble the other spring (P8658FH) onto the bolt
and secure with nut.
21. Tighten the nut approximately one thread beyond
the end of the bolt.
22. FH, FSK, CK, and CS models: Using a hook type
tool, insert the tool through the access hole in the end
of the handle grip. Secure the spring (P8678FS) and
pull it towards the opening, rotating slightly to allow the
spring to clear the pin. Hook the chain spring over the
pin. See Illustration 10.
22a. TN model: Hook the chain spring (P8678FS) and
pull the spring to near bottom of the handle and attach
the spring extension (P8679TN) to the chain at one end
and the handle pin at the other end.
23. Assemble snubber (P8654FS) and bolt (P8635FS)
to the handle. Assemble nut (T3171) and tighten so as
not to bind the assembly. See Illustration 11.
24. FH, FSK, CK and CS models: Check operation of
the tool by opening and closing.
24a. TN model: Check operation of the tool by opening
and closing. If operation is satisfactory, assemble a new
grip (P0380 ) onto handle.
Illustration 8
Illustration 9
Illustration 10
Illustration 11

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P18690
09/28/2009
HH..KK.. PPoorrtteerr®
8690 Series Disassembly and Assembly
Note: In the event the handle grip (P8681FH) was
removed and a new handle grip (P8680CK) with an
access hole in the bottom is being installed, perform the
following procedure to install the new handle grip.
a) ix a mild solution of liquid dishwashing soap and
water in a small cup. A mild rubber or plastic lubricant
may be used as an alternative. However, it must be one
that evaporates (dries completely) to avoid handle grip
slippage prior to use of the tool.
b) Place a mat or similar protective devise on the floor
to prevent damage to the tool or floor. Place the tool
vertically, head end down, onto the mat with the handle
straight up. Thoroughly wet the exterior of the metal
handle, where the grip will be installed, with the soapy
solution or lubricant. Thoroughly wet the inside of the
handle grip as well with the same solution. Quickly slide
the handle grip on as far as you can push by hand.
Using a soft-faced rubber mallet, continue installing the
handle grip until it bottoms out on the handle.
CAUTION: Use care not to damage the handle grip,
with the mallet, during assembly.
c) ake certain the handle grip is fully assembled onto
the handle. Allow the tool assembly to dry prior to use
to avoid slippage. A clamp is not required to secure the
handle grip to the handle.

P18690
09/28/2009
HH..KK.. PPoorrtteerr®
8690 series Handle Assembly
“A”
Page 6
3
317
15
13 12
18
1
30 28
27 3
3
19
11
4
5
34
26
33
29
21
23
22
14
20
10
9
17
25
20
6
27
32
8
15
7
14
2
13
16
31
24

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P18690
09/28/2009
HH..KK.. PPoorrtteerr®
8690 series Handle Assembly
Illustration "A": 8690 Series Ratchet Type Cutters Handle Assembly
Ref ty
Model Number
Description
8690CK 8690CS 8690FH 8690FSK 8690TN
Overall Length
28"
(711 mm)
29.75"
(756 mm)
29.25"
(743 mm)
27.5"
(699 mm)
36"
914 mm)
Part Number
11 P8681FH P8681FH P8681FH P8681FH Illustration "G" Handle Grip
21 P8680CK P8680CK P8680CK P8680CK Illustration "G" Handle Grip
34 P2666K P2666K P2666K P2666K P2666K Nut (8690CK: Qty. = 2)
42 ------ P0135SK P0135SK P0135CK P0135SK Bolt (Hex Head)
51 P8719CS P8719CS P8719CS P8719CS P8719CS Bushing
62 P8628FS P8628FS P8628FS P8628FS P8628FS Bolt (Hex Head)
71 P8634FS P8634FS P8634FS P8634FS P8634FS Bolt
81 P8635FS P8635FS P8635FS P8635FS P8635FS Bolt
92 ------ P8644FS P8644FS P8644FS P8644FS Spacer
10 2 ------ P8645FS P8645FS P8645FS P8645FS Spacer
11 1 P8648FS ------ ------ ------ ------ Clamp
12 1 P8652FS P8652FS P8652FS P8652FS P8652FS Chain Link
13 1 P8653FS P8653FS P8653FS P8653FS P8653TN Chain
14 2 P8654FS P8654FS P8654FS P8654FS P8654FS Snubber
15 2 P8658FH P8658FH P8658FH P8658FH P8658FH Spring
16 1 P8678FS P8678FS P8678FS P8678FS P8678FS Spring
17 2 T3171 T3171 T3171 T3171 T3171 Nut
18 1 Illustration "B" P8605F P8605F P8605F Illustration "G" Handle (Right)
-- -- P8661FH P8661FH P8661FH P8661FH P8661TN Handle Assembly (Includes 18 - 33)
19 1 P8606FH P8606FH P8606FH P8606FH Illustration "G" Handle (Left)
20 2 P8621FS P8621FS P8621FS P8621FS P8621FS Side Plate
21 1 P8624FS P8624FS P8624FS P8624FS P8624FS Sprocket
22 1 P8636FS P8636FS P8636FS P8636FS P8636FS Pawl
23 1 P8637FS P8637FS P8637FS P8637FS P8637FS Pawl
24 1 P8641FH P8641FH P8641FH P8641FH P8641FH Pin
25 1 P8642FS P8642FS P8642FS P8642FS P8642FS Bushing
26 1 P8644FS P8644FS P8644FS P8644FS P8644FS Spacer
27 2 P8646FS P8646FS P8646FS P8646FS P8646FS Bushing
28 1 P8674FS P8674FS P8674FS P8674FS P8674FS Spring
29 1 P8677FS P8677FS P8677FS P8677FS P8677FS Spring
30 2 P8683FH P8683FH P8683FH P8683FH P8683FH Retainer
31 1 P8685FH P8685FH P8685FH P8685FH P8685FH Pin
32 1 P8692FS P8692FS P8692FS P8692FS P8692FS Bolt
33 1 T3171 T3171 T3171 T3171 T3171 Nut
34 1 P2666K P2666K P2666K P2666K P2666K Nut
-- -- Illustration "B" Illustration "C" Illustration "D" Illustration "E" Illustration "F" Cutter Head Assembly

P18690
09/28/2009
HH..KK.. PPoorrtteerr®
8690 series Cutterheads
“B”
Page 8
“C”
“D”
8613CK Cutterhead
8613CS Cutterhead
8613FH Cutterhead
4
5
6
3
2
87
6
1
2
2
51
4
3
5
6
2
2
7
314
Illustration "B": 8613CK Cutterhead
Ref ty Part No. Description
12P8620CK Cheek
21P8611CK Blade
32 P2666K Nut
41 P6466 Pivot Bolt Nut
51P8610CK Blade and Handle Assembly
62P8643CK Spacer
71P8692CK Pivot Bolt
82P0135CK Bolt
Illustration "C": 8613CS Cutterhead
Ref ty Part No. Description
11P1747CN Cotter Pin
22P8610CS Blade
32P8779CS Spring Washer
41P8992CN Pivot Bolt
51P8993CN Pivot Bolt Nut
Illustration "D": 8613FH Cutterhead
Ref ty Part No. Description
12P0052GCW Lockwasher
22P8611FH Blade
32P8627FH Bolt
41P8650FH Keeper Assembly
51P1487W Dowel Pin
61P2693G Pivot Bolt Nut
71P8666FH Pivot Bolt

Page 9
P18690
09/28/2009
HH..KK.. PPoorrtteerr®
8690 series Cutterheads & TN Handle
“E”
“F”
8613FSK Cutterhead
8613TN Cutterhead
7
4
3
2
2
1
5
6
3
1
4
2
4
“G”
Illustration "E": 8613FSK Cutterhead
Ref ty Part No. Description
12P0052GCW Lockwasher
22P8610FSK Blade
31P0193TQ Pivot Bolt Nut
41P0194TQ Cotter Pin
52P8627FH Bolt
61P8650FSK Keeper Assembly
71P8666FSK Pivot Bolt
Illustration "F": 8613TN Cutterhead
Ref ty Part No. Description
11P1747CN Cotter Pin
21P7192Q Pivot Bolt
31P8993CN Pivot Bolt Nut
42P8610TN Blade
Model 8690TN Handle
12
2
34
Illustration "G": Model 8690TN Handle
Ref ty Part No. Description
11P8605TN Handle (Right)
22P0380 Grip
31P8606TN Handle (Left)
41P8679TN Spring Extension
51P8682TN Black Sleeve (not shown)

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Specifications subject to change without notice. H.K. Porter is a va uab e trademark of Cooper Industries in the U.S. and other countries. You are not permitted
to use the Cooper Trademarks without prior written consent of Cooper Industries.
CHT08-11761/Printed in USA 09/2009/P18690/Copyright © 2009 Cooper Industries