Huck 2600 User manual

Instruction Manual
Model 2600
Hydraulic Installation Tool
Huck International, Inc. 1993 -- Form HK914
U.S. Pat. Des. 363421 & Pat. Pending

EU Declaration of Conformity
Manufacturer:
Huck International Inc., Installation Systems Division, 85 Grand Street, Kingston, NY, 12401,
USA
Description of Machinery:
Model number 2400 series fastener installation tools
Model number 2400 series fastener installation tools
Model number 2400 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 Pattendon, 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: Renno Budziak
Position: Vice President of Engineering, Installation Systems Division
Place: Kingston, New York, USA
Date: May, 1996

Huck Model Series 2400, 2500 and 2600 (families) Sound Level
SEL = 75.8 dB (A)
peak value = 108.2 dB (C)
For an eight hour work day, installing 3000 typical Huck fasteners will result in an
equivalent noise level (Leq) of 66 dB (A).
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
Huck Model Series 2400, 2500 and 2600 (families) Vibration Level
For an eight hour work day, installing 3000 typical Huck fasteners will result in an
equivalent weighted RMS vibration level (Aeq) of 12.50m/s2.
To calculate the equivalent vibration level for other quantities of fasteners in an eight
hour period, use the formula:
Equivalent Vibration Level, Aeq (m/s2) = (n/480) x 2.00
where n = number of fasteners in eight hours, and 2.00(m/s2) = Aeq for 60 seconds
Test data to support the above information is on file at Huck International, Inc., Kingston, NY, USA. Vibration
measurements are frequency weighted in accordance with ISO 8041 (1990).

An important notice:
Operator must read and understand any
WARNING and Caution stickers/labels
supplied with equipment before connecting
equipment to any primary power supply - - as
applicable, the following sections each have
specific safety, and other, information:
• WARNINGS and CAUTIONS
• DESCRIPTION
• SPECIFICATIONS
• PRINCIPLE OF OPERATION
• PREPARATION FOR USE
• PREVENTIVE MAINTENANCE
• OPERATION AND TOOL HANDLING
As applicable, the disassembly and assembly
sections contain specific overhaul and safety
procedures.
Only persons who have read and understood all
applicable manuals or received training
approved by Huck International, Inc. will be
able to use Huck equipment with personal
safety and efficiency.
If you require additional information, contact
your local Huck representative or the nearest
office listed on the back cover.
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.
Italic type and underlining strengthens a
specific instruction.
WARNINGS
When operating Huck installation equipment
always wear approved eye protection.
Whenever within the working environment,
wear approved eye protection, with side
shields, to protect from anything that
breaks on the fastening system including:
Erupting fluid lines, flying fastener particles
or any other dirt/debris that could cause eye
injury. Where applicable, refer to ANSI
Z87.I - 1989.
Disconnect primary power source before
doing maintenance on Huck equipment.
• For electrically operated POWERIG®
Hydraulic Units, unplug the power cord
from the socket, If there is no plug, turn
off the power at the disconnect switch.
Follow lockout/tagout procedures in
force by your employer.
• For equipment powered by compressed
air, disconnect the air hose before doing
any maintenance.
• For hydraulic tools, or other hydraulic
equipment, disconnect the hydraulic
hoses from the hydraulic unit before
doing any maintenance.
If any equipment shows signs of damage or
leakage, DO NOT connect it to the primary
power supply (either electrical or
compressed air) - - and do not continue to
use equipment that develops erratic
symptoms. If equipment is damaged, or
there are other serious discrepancies,
affected equipment may rupture violently
- - parts may strike the operator, and/or
other personnel, and cause severe personal
injury. Ensure that ALL air and/or
hydraulic hose and/or electrical
plugs/connectors are correctly connected
before switching on power supply to
equipment. If incorrectly connected, the
tool may respond erratically and cause
severe personal injury. 7-1-97

CONTENTS
Description 1
Specifications 1
Principle of Operation 4
Preparation for Use 5
Checking and Adjusting Output Pressures 5
Power Source Connection Precaution 5
Operating Instructions 6
Maintenance 7
Preventive Maintenance 7
System Inspection 7
POWERIG ® Hydraulic Unit Maintenance 7
Tool Maintenance 7
Nose Assembly Maintenance 7
General Precautions 8
Troubleshooting 9 & 10
Spare Parts; Service Kit, 26OOKIT 10
Disassembly 11 & 12
Assembly 12, 15 & 16
Sub - Assembly Part Numbers and Notes 17
Conversion Kit, 123020; Hose Kits 18
Optional Hose Kit, 122854 21
ILLUSTRATIONS
Figure
1. Outline Dimensions 2
2. Main Components 3
3 Sectional View and Part Numbers 13 & 14
4. Removing Piston 19
5. Installing Piston 20
6. Optional Hose Kit, 122854 21
TABLES
1. Specifications 1
2. Service Kit Contents - - 2600KIT 18

DESCRIPTION
Model 2600 Hydraulic Installation Tool (HIT) with appropriate nose
assembly installs a wide range of Huck blind fasteners and HUCKBOLT®
Fasteners. This lightweight and compact mini tool is particularly adapted to
installing fasteners in limited clearance areas. Each tool is complete with
hydraulic hoses and couplings; electric switch and cord. The tool is
basically a cylinder and piston assembly. An unloading valve, designed to
relieve hydraulic pressure at end of the PULL stroke, is positioned by the
piston. End of piston rod is threaded and retaining nut and stop are
included for attaching nose assemblies.
Huck Hydraulic Installation Tools are designed to be powered by Huck
POWERIG® Hydraulic Units. The 2600 is designed to operate at
maximum of 5,700 psi (39,000 kPa) PULL and 2,800 psi (19,300 kPa)
RETURN pressures as supplied by Huck POWERIG Hydraulic Unit
Models 913, 918, 918-5, 940, 943, or equivalent.
A specific nose assembly is required for each fastener type and size. Nose
assemblies must be ordered separately - - see your Huck representative.
Table 1 - Specifications (1)
Length 9.40 in. (239 mm)
Width 2.65 in. (67 mm)
Height (incl. handle) 6.93 in. (176 mm)
Weight 7.30 lbs. (3.3 kg)
PULL pressure 5700 psi (39,300 kPa)
RETURN pressure 2800 psi (19,300 kPa)
Min. effective stroke 1.22 in. (31.0 mm)
(1) Length and weight does not include hoses/cord or nose assembly.
PulI capacity at 5700:13,840 lbs. (61.4 kN).
Power Source: Huck POWERIG Hydraulic Unit.
Hydraulic Fluid: Automatic transmission fluid. DEXRON II, or
equivalent.
1

2

3

4
PRINCIPLE OF OPERATION
Refer to Figure 2
An electric trigger controls PULL and RETURN strokes of tool. Press
trigger to direct hydraulic pressure to PULL side of piston - - fastener
installation begins.
At end of PULL stroke, before trigger is released, piston uncovers flats of
unloading valve - - pressure is unloaded by allowing fluid to flow back to
POWERIG hydraulic unit. Release trigger at end of PULL stroke when
fastener is installed - - pressure is directed to RETURN side of piston and
moves piston forward. Nose assembly, with tool, is pushed off fastener.
WARNINGS
Operators of Huck Installation equipment must always wear approved
eye protection.
Only Huck POWERIG ® Hydraulic Units are recommended as the
power source for Huck tools. Units that deliver high pressure for both
PULL and RETURN, and are not equipped with relief valves, are
specifically not recommended. Severe personal injury or damage to
equipment may occur when using other units.
Proper PULL and RETURN pressures are important for
proper function of Installation Tools. Severe personal injury
or damage to equipment may occur without correct pressures.
Gauge Set-up, P/N T-10280, is available for checking these
pressures using instructions furnished with T-10280 and in
applicable POWERIG Hydraulic Unit instruction manuals.
See Checking and Adjusting Output Pressures.
CAUTION
Keep dirt and other foreign matter out of hydraulic systems
of the tools, hoses, couplers and POWERIG hydraulic Unit.
Do not let hose fittings and couplers contact a dirty floor or
unclean working surface. Foreign matter in hydraulic fluid may
cause hydraulic unit valves and tool valves to malfunction.

5
PREPARATION FOR USE
CAUTION: Do not let disconnected hoses and couplers contact a dirty floor.
Dirt/debris in hydraulic fluid causes valve failure in the equipment.
Checking and Adjusting Output Pressures
POWERIG® Hydraulic Unit pressures must be checked and adjusted at first time
start-up, after overhauling the unit and when troubleshooting.
WARNINGS: Correct PULL and RETURN pressures are required for operator’s
safety and for installation tool’s function. Gauge Set-up, T-10280, is available for
checking pressures - - see tool’s Table 1 - Specifications and INSTRUCTION
MANUAL, T-10280. Failure to verify pressures may result in severe injury.
Be sure to connect tools hydraulic hoses to POWERIG Hydraulic Unit before
connecting tools switch control cord to unit. IF NOT CONNECTED IN THIS
ORDER, severe personal injury may occur.
1. Use Huck POWERIG Hydraulic Unit, or equivalent, that has been
prepared per INSTRUCTION MANUAL. Check both PULL and
pressures and adjust to pressures given in Table 1 - Specifications of
this manual. See both hydraulic unit’s and T-10280’s manuals.
2. First, turn hydraulic unit to OFF, then, disconnect unit’s power supply.
3. Connect tool’s switch electrical cord to hydraulic unit.
4. Connect hydraulic unit to power supply. Turn unit to ON. Hold tool
trigger depressed for 30 seconds; depress trigger a few times to cycle
tool and to circulate hydraulic fluid. Observe action of tool and check
for leaks. Turn unit to OFF.
5. Select nose assembly from NOSE ASSEMBLY SELECTION
CHART for fastener to be installed. Disconnect tool’s control switch
electrical cord from hydraulic unit; disconnect hydraulic unit from power
supply. Attach nose assembly to tool as given by instructions on NOSE
ASSEMBLY DATA SHEET.
6. Reconnect hydraulic unit to power supply; reconnect tool’s switch
control cord to unit. Check operation of nose assembly - - see NOSE
ASSEMBLY DATA SHEET - - install fasteners in test plate of
correct thickness with proper size holes. Inspect installed fasteners.
If fasteners do not pass inspection, see TROUBLESHOOTING
to locate and correct tool malfunction.

6
OPERATING INSTRUCTIONS
For safe operation. please read completely
PLEASE NOTE
Failure to understand WARNINGS may
cause severe personal injury.
Failure to understand CAUTIONS may
cause damage to structure and tool.
For additional safety information, see
safety section at front of manual.
WARNING
To avoid severe personal injury, be sure
of adequate clearance for operator’s
hands before proceeding with fastener
installation.
HUCKBOLT® Fastener Installation:
WARNING
Do not pull on a pin without placing
fastener/collar in a workpiece, and also,
collar chamfer MUST be out toward
tool
- - 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.
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 properly, jaws will be
damaged.
Place pin in workpiece and place collar
over pin - - see WARNING. (If Collar has
only one tapered end, that end MUST be
out toward tool - - not next to sheet.) Hold
pin and push nose assembly onto pin
protruding through collar until nose anvil
touches collar. Depress trigger - - hold
trigger depressed until collar is swaged and
pintail breaks. Release trigger. Tool will
go into its return stroke. Tool/nose are
ready for next installation cycle.
Blind Fastener Installation:
WARNING
Do not pull on a pin without placing
fastener in a workpiece - - fastener will
eject from front with velocity and force
when pintail breaks off or teeth/grooves
strip - - this may cause severe personal
injury.
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.
Fastener may be placed in workpiece or In
end of nose assembly - - see WARNING.
In either case, tool/nose must be held
against work and at right angles to it.
Depress trigger - - hold trigger depressed
until fastener is installed and pintail
breaks. Release trigger. Tool will go into
its return stroke. Tool/nose are ready for
next installation cycle.
CAUTIONS
BOM® blind fasteners jam in nose
assembly if pulled when not in
workpiece.
To avoid structural and tool damage, be
sure enough clearance is allowed for
nose assembly at full stroke.
Do not abuse tool by dropping it, using
it as a hammer or otherwise causing
unnecessary wear and tear.
Reasonable care of tools by operators is
an important factor in maintaining
efficiency and reducing downtime.

7
MAINTENANCE
Preventive Maintenance
NOTE - Refer to the applicable section for DISASSEMBLY or ASSEMBLY.
For extra information, refer to TROUBLESHOOTING and illustrations.
System Inspection
Operating efficiency of the tool is directly related to performance
of complete system, including tool with nose assembly, hydraulic
hoses, trigger and control cord, and POWERIG Hydraulic Unit.
Therefore, all effective preventive maintenance program includes
scheduled inspections of the system to detect and correct minor troubles.
1. Inspect tool and nose assembly for external damage.
2. Verify that hydraulic hose fittings and couplings, and electrical
connections are secure.
3. Inspect hydraulic hoses for damage. Replace hoses if damaged.
Do not use hoses to carry tools.
4. Observe tool, hoses and POWERIG Hydraulic Unit during
operation to detect abnormal heating, leaks or vibration.
POWERIG ® Hydraulic Unit Maintenance
Refer to the applicable POWERIG Hydraulic Unit Instruction Manual.
Tool Maintenance
At regular intervals, depending upon use, replace all seals, wipers and
back-up rings in tool. Service Kits and hoses should be kept on hand.
Inspect cylinder bore, piston and piston rod, and unloading valve for
scored surfaces, excessive wear or damage, and replace as necessary.
Always replace seals, wipers and back-up rings whenever the tool is
disassembled for any reason.
Nose Assembly Maintenance
Nose assemblies with UNITIZED™ jaws must be disassembled and
cleaned in mineral spirits or isopropyl alcohol. Do not let UNITIZED
jaws (urethane) soak in solvent. Do not use solvents that cause
urethane to swell. Dry components immediately after cleaning.
Use sharp “pick” to remove particles packed in jaw grooves.
Reassemble per instructions on applicable Nose Assembly Data Sheet.

8
MAINTENANCE (continued)
General Precautions
During disassembly and assembly, take the following precautions
to avoid damaging tool or components:
(A) A clean, well-lighted area should be available for servicing
the tool. Special care must be taken to prevent contamination
of hydraulic systems.
(B) Use soft materials, such as brass, aluminum or wood, to protect
the tool when applying pressure. Only standard hand tools are
required. Brass drifts, wood blocks, a vise with soft jaws and an
arbor press will prevent damaging tool. Standard tools available
Huck are listed in this manual.
(C) Apply 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 of an assembly.
(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 SUPER O-LUBE*, or equivalent lubricant,
on seals and mating surfaces to facilitate assembly and
to prevent damage to seals (SUPER O-LUBE is available,
in a tube as Part Number 505476, from Huck.)
* SUPER O-LUBE is a trademark of Parker Seal
(F) Rub SLIC-TITE TEFLON* thread compound, or equivalent,
on pipe threads, to aid assembly and sealing. CAUTION: DO
NOT USE TEFLON TAPE ON PIPE THREADS - -
shredded particles cause valves to malfunction. (TEFLON
compound is available from Huck in stick form as P/N 503237.)
TEFLON is a trademark of E.l. DuPont de Nemours & Co.
(G) All parts must be handled carefully and examined for damage
or wear. Always replace seals, wipers and back-up rings
when tool is disassembled for any reason. Components should
be disassembled and assembled in a straight line without bending,
cocking, or undue force. Disassembly and assembly procedures
outlined in this manual should be followed.

9
TROUBLESHOOTING
Always check out simplest possible cause of malfunction first. For example,
switch turned off or power cord not connected. Then proceed logically,
eliminating each possible cause until the defective circuit or part is located.
Where possible, substitute known good parts for suspected bad parts. Use
TROUBLESHOOTING chart as an aid in locating and correcting malfunction.
1. Tool fails to operate when trigger is depressed:
a. Inoperative POWERIG® Hydraulic Unit. See
applicable instruction manual.
b. Loose or disconnected control cord.
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
hydraulic unit and tool.
3. Tool leaks hydraulic fluid:
a. Depending on where leak occurs, defective or worn
O-rings, or loose hydraulic hose connection at tool.
4. Hydraulic couplers leak fluid:
a. Damaged or worn O-ring in coupler body.
See Figure 3.
5. Hydraulic fluid overheats:
a. Hydraulic unit not operating properly. See applicable
POWERIG Hydraulic Unit Instruction Manual.
b. Unloading valve installed backwards.
6. Tool operates erratically and fails to install fastener properly:
a. Low or erratic hydraulic pressure supply - air in system.
See applicable POWERIG Instruction Manual.
b. Damaged or excessively worn piston O-ring in tool.
c. Unloading valve installed backwards.
d. Excessive wear or scoring of sliding surfaces of tool parts.
e. Excessive wear of unloading valve.

10
TROUBLESHOOTING (Continued)
7. Pull grooves on fastener pintail. stripped during pull stroke:
a. Operator not sliding jaws completely onto fastener pintail.
b. Incorrect fastener length.
c. Worn or damaged jaw segments.
d. Metal particles accumulated in pull grooves of jaw segments.
e. Excessive sheet gap.
f. Nose assembly not properly attached - see NOSE ASSEMBLY
DATA SHEET
8. Collar Of HUCKBOLT@ Fastener not completely swaged:
a. Improper tool operation. See 6.
b. Scored anvil in nose assembly.
9. Shear collar on Huck blind fastener not properly installed:
a. Improper tool operation. See 6.
b. Worn or damaged driving anvil in nose assembly.
10.Tool “hangs-up” on swaged collar of HUCKBOLT Fastener:
a. Improper tool operation. See 6.
b. RETURN pressure too low.
c. Nose assembly not properly attached - see NOSE DATA
SHEET.
11.Pintail of fastener fails to break:
a. Improper tool operation. See 6.
b. Pull grooves on fastener stripped. See 7.
c. Worn piston and/or unloading valve.
d. Hydraulic pressure too low.
e. Damaged O-ring on piston.
12.Operator cannot slide nose assembly (completely) onto fastener:
a. Broken pintails jammed in tool. Install pintail tube if broken
pintails will pass through.
Spare Parts and Service Kit
The quantity of spare parts that should be kept on hand varies with
the application and number of tools in service. Spare service kits,
2600KIT, containing perishable parts such as seals, back-up rings,
etc., should be kept on hand at all times - - see p. 18.

11
DISASSEMBLY
Refer to MAINTENANCE: General Precautions and illustrations.
The following procedure is for complete disassembly - -
disassemble only sub-assemblies necessary to check and replace
damaged seals, wipers, back-up rings and components. Always
replace seals, wiper, O-rings and back-up rings of disassembled
sub-assemblies- - see CAUTION at beginning of ASSEMBLY.
WARNING
Be sure electric control cord is disconnected from
POWERIG ® Hydraulic Unit before disconnecting tool’s
hoses from hydraulic unit. ALWAYS disconnect connections
in this order to prevent possible severe personal injury.
1. Disconnect electrical connector. Uncouple tool
hydraulic hoses
2. Remove nose assembly.
3. Unscrew coupling nipple and coupling body. Drain hydraulic
hoses into container - - discard fluid.
4. Push rearward on piston until remaining hydraulic fluid is
drained into container - - discard fluid.
5. NOTE: Do not remove hydraulic hoses from tool unless
replacing hoses. If necessary to remove hoses, uncover hose
fittings by sliding plastic shrouds back.
6. Loosen strain relief grommet. To remove switch - -
loosen set screw and carefully pry switch out with a small
screwdriver. Loosen two wires at rear of switch and
remove it from cord. Pull cord out and remove grommet.
Disassemble electrical connector to replace connector, or
to rewire it.

12
DISASSEMBLY (continued)
7. Remove pintail deflector, 122766, - - twist and pull in the
same motion.
8. Remove socket screw from rear gland and barbed retainer.
9. Insert two 5/16 pins in opposite holes in rear of barbed
retainer - - unscrew retainer.
10.Remove dump valve from rear of cylinder.
11.See Fig. 5 - - place Spacer, 123112, over threaded end of
piston. Screw Piston Assembly Tool onto piston. Press or
drive piston, front gland and rear gland out of cylinder - -
place hose ends in container to catch oil that is forced out by
piston.
12.Use a small diameter dull pointed rod to remove all O-rings
and seals - - clean parts and examine for wear and other
defects.
ASSEMBLY
Refer to appropriate illustrations and MAINTENANCE. General
Precautions - - clean out O-ring grooves and reinstall perishable
parts - - see below.
CAUTION: See special instructions in step 5. below for
replacing seals. Use Service Kit - - always replace seals,
wipers, O-rings and back-up rings of disassembled sub-
assemblies.
1. Install GLYD RING assembly on piston; place the special
O-ring in groove; place GLYD RING on top of it. Roll
GLYD RING’S diameter to a diameter smaller than piston
before installing ring - - this is to insure that ring stays in
place during piston installation.

13

14

15
ASSEMBLY (continued)
2. Taking care not to pinch inner ring, press POLY-SEAL into
front gland housing. Install O-ring and back-up ring on front
gland assembly.
3. See Fig. 6 -- thread Assembly Tool, 123111, onto piston.
4. Lubricate POLY-SEAL’S inside diameter.
NOTE: To keep POLY-SEAL in front gland, push front wiper
housing into front gland. Hold housing against POLY-SEAL
while pressing front gland/POLY-SEAL onto piston.
5. CAUTION: Be sure that seal does not hang upon edge of
piston chamfer. See NOTE above - - press with suitable
pressing drift against back of piston. White holding wiper
housing in place, guide POLY-SEAL onto piston.
6. Press wiper into groove on wiper housing.
NOTE: Thread retaining nut onto cylinder to act as stand-off.
7. Lubricate piston’s outer seal and POLY-SEAL.
8. See Fig. 6 - - install GLYD RING Insertion Tool, 121694-
2600 into cylinder to prevent damage to GLYD RING
Assembly.
9. Carefully drive, or press, piston into cylinder.
10.Remove Tools, 121694-2600 and 123111. Install relief valve
into piston with four flats toward REAR of tool.
11. Install the following in rear gland: O-ring and back-up ring;
POLY-SEAL, spacer and retaining ring; press assembled
gland into cylinder; press wiper into groove in gland.
12.Align recess in rear gland with groove in cylinder. Install
locking disc.
13.Screw barbed retainer into cylinder until it bottoms out.
Back retainer out to first visible threaded hole in rear gland.
Install and tighten locking screw to 40+/- 3in. lbs.