declaration of conformity safety instructions instruction manual ...hk1103).pdf · ensure there are...

November 18, 2016HK1103

Makers of Huck®, Marson®, Recoil®Brand Fasteners, Tools & Accessories

Declaration of Conformity2

Safety Instructions3

Description4

Specifications4

Outline Dimensions5

Principle of Operation6

Sticker Placement6

Preparation for Use7

Operating Instructions8

Maintenance 9

Troubleshooting9

Standard Tools Available10

Adjustments10

Disassembly and Assembly Procedures

11-12

Tool Components Drawings13-20

Instruction Manual CCX and CCXS Collar Cutters

-06 to -12

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CCX and CCXS Collar Cutters (HK1103)

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Safety Instructions

I. GENERAL SAFETY RULES:1. Ahalfhourlonghands-ontrainingsessionwithqualifiedpersonnelis

recommendedbeforeusingHuckequipment.2. Huckequipmentmustbemaintainedinasafeworkingconditionatall

times.Toolsandhosesshouldbeinspectedatthebeginningofeachshift/dayfordamageorwear.AnyrepairshouldbedonebyaqualifiedrepairmantrainedonHuckprocedures.

3. Formultiplehazards,readandunderstandthesafetyinstructionsbeforeinstalling,operating,repairing,maintaining,changingaccessorieson,orworkingneartheassemblypowertool.Failuretodosocanresultinseriousbodily injury.

4. Onlyqualifiedandtrainedoperatorsshouldinstall,adjustorusethecutting-off/crimpingpowertool.

5. Donotmodifythiscutting-off/crimpingpowertool.Thiscanreduceeffectivenessofsafetymeasuresandincreaseoperatorrisk.

6. Donotdiscardsafetyinstructions;givethemtotheoperator.7. Donotusecutting-off/crimpingpowertoolifithasbeendamaged.8. Toolsshallbeinspectedperiodicallytoverifyallratingsandmarkings

required, and listed in the manual, are legibly marked on the tool. The employer/operatorshallcontactthemanufacturertoobtainreplacementmarkinglabelswhennecessary.Refertoassemblydrawingandpartslistforreplacement.

9. Toolisonlytobeusedasstatedinthismanual.Anyotheruseisprohibited.10. OnlygenuineHuckpartsshallbeusedforreplacementsorspares.Useof

anyotherpartscanresultintoolingdamageorpersonalinjury.11. Neverremoveanysafetyguardsorpintaildeflectors.12. Checkclearancebetweentriggerandworkpiecetoensurethereisnopinch

pointwhentoolisactivated.Remotetriggersareavailableforhydraulictoolingifpinchpointisunavoidable.

13. Donotabusetoolbydroppingorusingitasahammer.Neverusehydraulicorairlinesasahandleortobendorprythetool.Reasonablecareofinstallationtoolsbyoperatorsisanimportantfactorinmaintainingtoolefficiency,eliminatingdowntime,andpreventinganaccidentwhichmaycauseseverepersonalinjury.

14. Neverplacehandsbetweencutting-off/crimpingpowertoolandworkpiece.Keephandsclearfromfrontoftool.

II. PROJECTILE HAZARDS:1. Disconnectthecutting-off/crimpingpowertoolfromenergysource

when changing inserted tools or accessories.2. Beawarethatfailureoftheworkpiece,accessories,ortheinsertedtoolitselfcangeneratehighvelocityprojectiles.

3. Alwayswearimpactresistanteyeprotectionduringtooloperation.Thegradeofprotectionrequiredshouldbeassessedforeachuse.

4. For overhead work, wear a safety helmet.5. Ensurethattheworkpieceissecurelyfixed.6. The risk to others should also be assessed at this time.7. Beawareoftheriskofbeingexposedtotheejectionofcuttingsorchips.8. Beawarethatworkingonbrittlematerialcancauseharmfulsplinters.

III. OPERATING HAZARDS:1.Useoftoolcanexposetheoperator’shandstohazardsincluding:crushing,impacts,cuts,abrasionsandheat.Wearsuitableglovestoprotecthands.

2.Operatorsandmaintenancepersonnelshallbephysicallyabletohandlethebulk,weightandpowerofthetool.

3. Hold the tool correctly and be ready to counteract normal or sudden movements with both hands available.

4.Maintainabalancedbodypositionandsecurefooting.

5.Releasetriggerorstopstartdeviceincaseofinterruptionofenergysupply.6.Useonlyfluidsandlubricantsrecommendedbythemanufacturer.7. Avoid direct contact with the inserted tool as it can become hot.8.Sharptoolsshallalwaysbeused.9. Beawareofriskofwhippingcompressedairhose.10.Be aware of risk of cutting with tools with large dimensions.

IV. REPETITIVE MOTION HAZARDS:1. Whenusingcutting-off/crimpingpowertool,theoperatorcanexperiencediscomfortinthehands,arms,shoulders,neckorotherpartsofthebody.

2. Whenusingtool,theoperatorshouldadoptacomfortableposturewhilemaintainingasecurefootingandavoidawkwardoroffbalancedpostures.

3. Theoperatorshouldchangepostureduringextendedtaskstohelpavoiddiscomfort and fatigue.

4. Iftheoperatorexperiencessymptomssuchaspersistentorrecurringdiscomfort,pain,throbbing,aching,tingling,numbness,burningsensationsorstiffness,thesewarningsshouldnotbeignored.Theoperatorshouldtelltheemployerandconsultaqualifiedhealthprofessional.

V. ACCESSORIES HAZARDS:1. Disconnecttoolfromenergysupplybeforechanginginsertedtoolor

accessory.2. Useonlysizesandtypesofaccessoriesandconsumablesthatarerecommended.Donotuseothertypesorsizesofaccessoriesorconsumables.

VI. WORKPLACE HAZARDS:1. Beawareofslipperysurfacescausedbyuseofthetoolandoftriphazards

caused by the air line or hydraulic hose.2. Proceed with caution while in unfamiliar surroundings; there could be

hiddenhazardssuchaselectricityorotherutilitylines.3. Thecutting-off/crimpingpowertoolisnotintendedforuseinpotentially

explosiveenvironments.4. Toolisnotinsulatedagainstcontactwithelectricalpower.5. Ensuretherearenoelectricalcables,gaspipes,etc.,whichcancausea

hazardifdamagedbyuseofthetool.

VII. DUST AND FUME HAZARDS:1. Dustandfumesgeneratedwhenusingcutting-offandcrimpingpower

toolscancauseillhealth;riskassessmentandimplementationofappropriatecontrolsforthesehazardsareessential.

2. Risk assessment should include dust created by the use of the tool and thepotentialfordisturbingexistingdust.

3. Operateandmaintainthecutting-offorcrimpingpowertoolasrecommendedintheinstructionhandbook,inordertominimizedustorfume emissions.

4. Directtheexhaustsoastominimizedisturbanceofdustinadust-filledenvironment.

5. Wheredustorfumesarecreated,thepriorityshallbetocontrolthematthepointofemission.

6. Allintegralfeaturesoraccessoriesforthecollection,extractionorsuppressionofairbornedustorfumesshouldbecorrectlyusedandmaintained.

7. Userespiratoryprotectioninaccordancewithemployer’sinstructionsandasrequiredbyoccupationalhealthandsafetyregulations.

VIII. NOISE HAZARDS:1. Exposuretohighnoiselevelscancausepermanent,disablinghearing

lossandotherproblemssuchastinnitus,thereforeriskassessmentandtheimplementationofpropercontrolsisessential.

2. Appropriatecontrolstoreducetheriskmayincludeactionssuchasdampingmaterialstopreventworkpiecefrom‘ringing’.

3. Usehearingprotectioninaccordancewithemployer’sinstructionsandasrequiredbyoccupationalhealthandsafetyregulations.

4. Operateandmaintaintoolasrecommendedintheinstructionhandbooktopreventanunnecessaryincreaseinthenoiselevel.

5. Select,maintainandreplacetheconsumable/insertedtoolasrecommendedtopreventanunnecessaryincreaseinnoise.

6. Ifthepowertoolhasasilencer,alwaysensurethatitisinplaceandingoodworkingorderwhenthetoolisbeingoperated.

IX. VIBRATION HAZARDS:1.Exposuretovibrationcancausedisablingdamagetothenervesandbloodsupplytothehandsandarms.

2.Wearwarmclothingwhenworkingincoldconditions.Keephandswarmanddry.

3. Ifnumbness,tingling,painorwhiteningoftheskininthefingersorhands,stopusingthetool,tellyouremployerandconsultaphysician.

GLOSSARY OF TERMS AND SYMBOLS:

- ProductcomplieswithrequirementssetforthbytherelevantEuropeandirectives.

- READ MANUALpriortousingthisequipment.

- EYE PROTECTION IS REQUIRED while using this equipment.

- HEARING PROTECTION IS REQUIRED while using this equipment.

Notes:areremindersofrequiredprocedures.Bold, Italic type and underlining: emphasizesaspecificinstruction.

WARNINGS: Must be understood to avoid severe personal injury.

CAUTIONS: show conditions that will damage equipment and or structure.

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CCX and CCXS Collar Cutters (HK1103) Description

Series CCX-QD Hydraulic Collar Cutters are designed to remove LGP® HuckBolt®fastenerswithflangedtitanium collars, and shouldbepoweredbyaHuck Powerig® hydraulic unit. The cuttersoperateon6,000psi(413.7 bar)PULLpressureassuppliedbyaHuck Powerig hydraulic unit.Setthecorrectpressureaccording to theapplicablePowerig instruction manual.

Air-triggered CCX-QD cutters are designed for use with Powerig model 968.

Electric-triggered CCX-QD cutters are designed for use with Powerig models 913F, 918, and 940.

CCX (Non-SleeveThreaded) andCCXS (SleeveThreaded) style

Specifications

POWER SOURCE: HuckPOWERIG®HydraulicUnit

HOSE KITS: UseonlygenuineHUCKHoseKitsratedat10,000psi(689.5 bar)workingpressure.

MAX OPERATING TEMP: 125° F (51.7° C)

MAX FLOW RATE: 2gpm(7.6 l/m)

MAX PULL PRESSURE: 6,000psi(414 bar)

WEIGHT:6CC&8CCseries:1.9lbs(0.86 kg)10CC&12CCseries:3.81lbs(1.72 kg)

HYDRAULIC FLUID: HydraulicfluidshallmeetDEXRON® III, DEXRON VI, MERCON®, Allison C-4 or equivalent Automatic Transmission Fluid (ATF)specifications.Fire-resistantfluidmaybeusedifitisanester-basedfluidsuchasQuintolubric®HFDorequivalent.Water-basedfluidshallNOTbeusedasseriousdamagetoequipmentwilloccur.

Where the following trade names are used in this manual, please note:DEXRON is a registered trademark of General Motors Corporation.Loctite is a registered trademark of Henkel Corporation, U.S.A.LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.MERCON is a registered trademark of Ford Motor Corp.MOLYKOTE is a registered trademark of Dow Corning CorporationNever-Seez is a registered trademark of Bostik, Inc. Quintolubric is a registered trademark of Quaker Chemical Corp.Slic-tite is a registered trademark of LA-CO Industries, Inc. Spirolox is a registered trademark of Smalley Steel Ring CompanyTeflon is a registered trademark of E. I. du Pont de Nemours and Company.Threadmate is a registered trademark of Parker Intangibles LLC.TRUARC is a trademark of TRUARC Co. LLC.Vibra-Tite is a registered trademark of ND Industries, Inc. USA.

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Outline Dimensions

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Figure 1

Inches (mm)

6CCX & 8CCXSeries

Inches (mm)

10CCX & 12CCXSeries

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Principle of OperationThe hydraulic hose and trigger control cord are connected to the Huck Powerig®hydraulicpowerunit.Thetrigger,whendepressed,controlsthePUSHstrokeofthetool.Hydraulicpressureisdirectedtothepiston,which then moves forward.

Fastener removal (collar cutting) begins as the lever moves, forcing the collar against stationary blades, cuttingthecollar.Whenthecuttingiscompleted,thetriggerisreleased.Springpressuremovesthepistonrearwardtothestartingposition;andthecutterisreadyforthenextcuttingcycle.

AllCollarCuttersareequippedwithimportantinformation,safety,andWARNINGstickers.Ifastickerbecomesunreadable,damaged,worn,orismissing,areplacementstickermustbeorderedandplacedasshown.

Sticker Placement

590273Warning

Sticker

590245 Caution Sticker 590517 HUCK Year of Manufacture Sticker

590513 Pinch Point Sticker

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Preparation for Use

1. UseaHuckPowerighydraulicunit,orequivalent,thathasbeenpreparedforoperationperapplicableinstructionmanual.CheckthePULLandRETURNpressures,andadjustasrequired.

2. ScrewthePULLpressurehose,withthecouplernipple,intotheportoftool.

3. Adjustthetriggerassemblyonthepressurehoseforconvenientpositionifrequired.

4. Connect the tool hose to the Powerig.

5. Connect the trigger control cord or air line to the Powerig.

6. ConnectthePowerigtothepowersupply(airorelectric).Depressthetriggerafewtimestocyclethetoolandtocirculatethehydraulicfluid.Observetheaction of the tool and cheek for leaks. Disconnect the toolfrompowersupply.

CAUTIONS:Keep dirt and other foreign matter out of the hydraulic systems of tools, hoses, couplers Powerig® hydraulic unit.

Do not let hose and couplers contact a dirty floor or unclean work surface. Foreign matter in hydraulic fluid may cause valve failures in the tool and Powerig.

Do not use Teflon® tape on pipe threads. Tape can shred, resulting in malfunctions.

Apply Parker Threadmate®, Loctite® 567, or Slic-Tite® to male pipe threads, hose fitting threads, and quick connect fittings (per manufacturer’s instructions) to prevent leaks and to ease assembly.

Do not abuse the 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 tool efficiency and reducing downtime.

WARNINGS: Huck recommends that only Huck Powerigs be used as a power source for Huck installation equipment.

When operating Huck equipment always wear approved eye protection. Severe eye injury may occur if eyes are not protected.

Tool moves forcibly while cutting collars. Be sure there is adequate clearance for the tool and the operator’s hands before proceeding. Otherwise, severe personal injury may result.

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 could result in serious personal injury.

Use Huck Pressure Gauge T-124833CE for setting pressures. Improper pressure settings may result in severe personal injury.

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Operating Instructions

Unequalloadingofthebladescausedbymisalignmentisthecauseofmosttoolmalfunctions.Experiencewillshowthemostefficientprocedureineachsituation.Collarsmustbecutonthefirstattempt.Repeatedcycling of the tool is likely to cause blade damage. The bladesfollowthepreviousbladepathwithoutcutting.

1. Place tool over fastener to be removed. (Figure 5 or 6)Checkpositionofbladesbeforetriggeringtool.

2. Depresstooltrigger,andreleaseitwhencuttingactionstops.Removethetool.

3. If tool is adjusted correctly for swaged condition of the collar, one stroke will remove the collar. (See Adjustmentsfordetailedinstructions.)Whencollariscutbutstillattachedtofastener,useappropriatehandtoolstocompletecollarremoval.

4. Taptheendofthefastenerwithsoft-facedmallettoremove it from the hole.

Removing Partially Cut Collars (Figure 7)

1. Place the G57F over the fastener to be removed, and squeezethehandles,closingthebladesaroundthepin.

2. Move the G57Fhandlesupanddownasshownindirectionofarrowsuntilthecollarseparatesfromthepin.

WARNING: The tool moves forcibly while cutting collars. Be sure there is adequate clearance for the tool and the operator’s hands before proceeding. Otherwise, severe personal injury may result.

Cut Collar RemovalFigure 7

90°

CAUTIONS: Tool must be held perpendicular to sheet. Tool heads must be flat against sheet.

Tool must be centered on collar to ensure proper cutting action.

If a collar is partially cut, do not force the cutter over collar. This will damage the locating pins in the tool pocket. See Removing Partially Cut Collars below.

To prevent structural and tool damage, be sure there is enough clearance for the tool to move while cutting collars.

Check the tool for collar segments after each cutting stroke. Segments not removed from tool will cause damage to the tool and the fastened structure.

Figure 6

90°45°

Offset Collar Cutting Position

Figure 5

90°

Standard Collar Cutting Position

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Maintenance

GOOD SERVICE PRACTICESTheoperatingefficiencyofanyinstallationorremovaltooldependsuponpropermaintenanceandgoodservicepractices.Toolsshouldbeservicedbypersonnelwho are thoroughly familiar with them and how they operate. Service the tool in a clean, well-lighted area. Givespecialcaretopreventcontaminationofpneumaticandhydraulicsystems.Carefullyhandleallpartsandcomponents.Beforereassembly,examinehoses,parts,andcomponentsfordamageandwear;replacewhennecessary.

Disassembleandassembletoolcomponentsinastraightline without bending, cocking, or undue force. Follow the disassemblyandassemblyproceduresinthismanual.Appropriatehandtoolsandsoftmaterialstoprotecttoolmust be available. Only standard hand tools are required. A half-inch brass drift, and wood block and vise with soft jawswillpreventdamagingtools.NOTE: As experience shows, components such as jaws should be kept on hand for repairs. Keep perishable parts such as O-rings and seals on hand for replacement whenever the tool is disassembled.

PREVENTIVE MAINTENANCEWithpropercare,thecutterwillremove200collarsbeforeitmaybenecessarytoreplacetheblades.Lubricate the area between the housing, wedge, and leverwithNever-Seezeveryfiftyfasteners.After200fasteners, the cutter should be disassembled, cleaned

inmineralspirits,andblowndrywithcompressedair.Whenpartsarecompletelydry,coatthespecifiedareaswithmolybdenumdisulfatesolution(suggestedproductisMOLYKOTE®106).Whenreplacingabladeset,coatitwithNever-Seezduringassembly.

SYSTEM INSPECTIONTheoperatingefficiencyofthetoolisdirectlyrelatedtotheperformanceofthecompletesystem,includingthe tool, hydraulic hoses, trigger assembly, and the Powerig®hydraulicunit.Therefore,aneffectivepreventivemaintenanceprogramincludesscheduledinspectionsofthesystemtodetectandcorrectminortroubles.

Inspectthetoolforexternaldamage.Verifythathosesandfittings,andtriggerconnectionsaresecure. Inspecthydraulichosesforsignsofdamage;replaceifnecessary.Inspecttool,hoses,andPowerigduringoperationtodetect abnormal heating, leaks, or vibration.

POWERIG MAINTENANCEMaintenanceinstructionsandrepairproceduresareintheapplicablePowerigInstructionManual.

TOOL MAINTENANCEWheneverdisassembled,andatregularintervals,replaceallsealsinthetool.Sparesealsandpartsshouldbekepton hand.

Inspectcylinderboreandpistonforscoredsurfaces,excessivewear,anddamage;replaceasnecessary.

CAUTION: Always replace all seals, wipers, O-rings, and Back-up rings when the tool is disassembled for any reason.

TroubleshootingAlwayscheckthesimplestpossiblecause(suchasalooseordisconnectedtriggerline)ofamalfunctionfirst.Thenproceedlogically,eliminatingotherpossiblecausesuntilthecauseisdiscovered.Wherepossible,substituteknowngoodpartsforsuspecteddefectiveparts.Usethistroubleshootinginformationtoaidinlocatingandcorrectingtrouble.1. Cutter fails to operate when trigger is pressed.

a. InoperativePowerig® hydraulic unit. See applicableinstructionmanual.

b. Loose air or electric connections.c. Damaged trigger assembly.d. Looseorfaultyhydraulichosecouplings.

2. Cutter blades do not cut through collar.a. Reversed hydraulic hose connections between

hydraulic unit and collar cutter.3. Cutter leaks hydraulic fluid.

a. Defective seals or loose hose connections at tool.4. Hydraulic couplers leak fluid.

a. DamagedorwornO-ringsincouplerbody.Seeillustration.

5. Hydraulic fluid overheats.a. PowerignotoperatingproperIy;seeunit’s

manual.b. Pumpmotorrotationreversed.Seeunit’s

manual.6. Cutter operates erratically and fails to cut collar.

a. Loworerratichydraulicpressuresupply; air in system.

b. DamagedorwornpistonPolysealincutter.c. Excessivewearonslidingsurfacesoftoolparts.d. Excessivewearofbladesordamage.

7. Cutter blades fail to open when trigger is released.a. Returnspringisweakorbroken.

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Standard Tools Available

The Collar Cutter is designed to remove a fully swaged collarinonestrokewhenadjustedwiththesetpluggaugethatissuppliedwiththetool.(Setpluggagepartnumberis130045-*,where*=fastenersize.e.g.130045-6isshippedwithcutter6CCX;130045-10isshippedwithcutter10CCX,etc.)TheCollarCuttercanbeadjustedtocutpartiallyswagedcollarsbyincreasingtheopeningbetweentheleverandtheblades.NOTE: See the applicable tool drawing for set plug gauge part number. Check fastener size.

LEVER ADJUSTMENTFully Swaged Collar1. Adjustthegapopeningbetweenthebladesand

theleverbyinsertinga3/16”hexkeythroughtheholeintheendcapandintothepistonhex.The turning key moves the wedge and lever simultaneously. Adjust until a slight interference isfeltontheflangediameterofthecollarbetween the blade and the lever.

2. Checkthetoolonatestplatewithproperlyinstalled fasteners. See Additional Procedures After Adjustment.

3. Fillthetoolwithfluidandreplacethehosekit.

Partially Swaged CollarSimulatethe“partiallyswaged”conditionbyinstallingfastenersinatestplateusingspacers(shimstock)equallyspacedundertheanvilofthenose assembly. Install the fasteners with various shimsuntilthedesired“partialswage”isobtained.1. Follow Fully Swaged Collar steps1–3.2. Remove the gauge.

Additional Procedures After AdjustmentAfterfinaladjustmentshavebeenmade,ifthecollar cannot be cut with one stroke, remove the collarwithappropriatehandtools.SeeFigure7.Ifincreasedefficiencyisrequired,morethanonecuttercanbeused:oneadjustedtocutfully swaged collars and one adjusted to cut partially swaged collars.

Adjustments

LUBRICANTS & SEALANTSApplyParkerThreadmate®, Loctite® 567, or Slic-Tite® to malepipethreads—permanufacturer’sinstructions—toeaseassemblyandtopreventleaks.P/N Description502723 SUPER-O-LUBE505565 Never-Seez503237 Slic-Tite508517 Threadmate

CAUTION: Do not use Teflon® tape on pipe threads. Tape can shred, resulting in malfunctions.

PART NO. DESCRIPTION USE ON502865 Truarc Pliers #0200 500989 & 500991502655 9/64”HexKey 500054502296 3/16”HexKey 119513 & 123703

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Disassembly Procedure

Refer to Maintenance and the Assembly Drawings in thismanual.Thefollowingprocedureisforcompletedisassembly. Disassemble only those subassemblies necessarytocheckandreplacedamagedsealsandcomponents.1. Uncouplethehydraulichoseconnectorandelectrical

control cord connector or air connector from the powersource.

2. Usethe1/8”hexkeytoremovethesocket-headcapscrew from blade. Remove blade from the housing.

3. Useamalletandbrassrodtotapthesplitpinfromthehousing.Removethetorsionspring.

4. UseTRUARCpliers#0200to remove the retaining ringfromthepin.

5. Pushthepinfromthehousing.Removethelever.

6. Remove the hydraulic hose from the elbow. Remove the quick disconnects.

7. Unscrewtheelbowfromthecap.Holdthecapwrenchflatstopreventthecapfromturning.

8. Unscrewcapretainerfromthecap.Holdtheflats.

9. READ WARNINGS above. Remove the retaining ring usingapointedtool.

10. READ WARNINGS. Usethe3/16”hexkeytounscrewthepistonfromthewedge.

11.Carefullyreleasethepressurefromthecap,piston,andspring.Removethesecomponentsfromthehousing.

12.Useasmall-diameterrodwithadullpoint to remove PolysealandO-ringsfromthecomponents.

13.Unscrewbothflatheadscrewsfromthehousingclamp.Removehoseandtriggerassembly.Removehydraulichoseandspacer.Unscrewnippleandreducing bushing.

See Assembly Drawing Switch and Electric Cord Kit

14. Loosen the strain relief that is holding the electric cord.Unscrewthestrainrelieffromtheswitchhousing.

15.Useathinscrewdrivertoprythetriggerswitchassembly from the housing.

16.Unscrewbothsocketscrewsattachingthewirestothe switch. Pull the cord from the switch and strain relief.

17. Loosen both screws on the face of the connector; disassemble the connector. Loosen the screws and remove the wires.

See Assembly Drawing Air Trigger and Hose Assembly

18.Loosenthelargehexontheairfittingandthehexonthedisconnectfitting.Removethetubing.Unscrewtheairfittingfromthetriggerhousingassembly.

19.Unscrewthehosefitting;thenunscrewtheairtriggerassembly.

20. Disassemble the air trigger assembly.

Store all re-usableparts(screwsanddisassembledcomponents)inaclean,dryarea.

CAUTIONS: Replace all seals, wipers, and rings when the tool is disassembled for any reason, and at regular intervals, depending on severity and length of use.

WARNINGS: Be sure hose and trigger assembly is disconnected from the Powerig® hydraulic unit before cleaning or replacing worn or damaged components. Severe personal injury may occur if not disconnected.

If the cap, piston, and spring are not restrained, they will forcibly eject from the housing. Disassemble using the following steps to prevent this:1. If the wedge is broken from the piston, or

if it has been unscrewed from the piston, the CAP MUST BE HELD FIRMLY WHILE THE RETAINING RING IS BEING REMOVED.

2. If the retaining ring has been removed before the wedge is unscrewed from the piston, the CAP MUST BE HELD FIRMLY WHILE THE WEDGE IS BEING UNSCREWED. SEVERE PERSONAL INJURY MAY RESULT IF THE UNRESTRAINED SPRING FORCIBLY EJECTS THE CAP AND PISTON FROM THE HOUSING.

12

CCX and CCXS Collar Cutters (HK1103) Assembly Procedure

Cleanallcomponentswithmineralspirits.Inspectforwearanddamage;replaceasnecessary.Replace all seals of disassembled components. UseO-ringsandPolysealssuppliedinSparePartsServiceKits. See applicableservicekitpartslist.Smear LUBRIPLATE® 130-AA (Huck P/N 502723) or SUPER-O-LUBE® (Huck P/N 505476) on rings,polyseal,andmatingcomponentsto facilitate assembly. Whenassemblingthetool,doNOT

damagetheO-ringorthepolyseal.See Assembly Drawing Air Trigger and Hose Assembly1. Assemble air trigger assembly.

2. Screwhosefittingintohousing.Screwairtriggerassemblyintohousing.Tightenbothparts.

3. Startairfittingontohosefitting.Pushtubingintofitting,thentightenfitting.

4. Pushotherendoftubingintodisconnectfittingandtighten.

See Assembly Drawing Switch and Electric Cord Kit5. Withconnectordisassembled,pushcordthrough

topofconnector.Pushbothwiresintoholesinbase;tighten both retaining screws.

6. Squeezeassembledbaseandtoptogetheruntilbothconnecting screws are seated. Continue tightening screwsuntilcordisfirmlygripped.

7. Screw strain relief into housing and tighten.

8. Push cord through strain relief. Push each wire into an attaching hole in back of electric switch assembly and tighten both screws.

9. LubricatetheO-ringand,usingarborpress,presselectric switch into housing. Tighten the strain relief on the cord.

10. Position air trigger hose/electric switch cord and hosespacerinlowerhalfofhousingclamp.Puthydraulichoseinclampnearcutterendofhose.Allowextraspaceonhosesohoseguardcanbepulledbacktoallowaccesstohexhosefitting.

11. Placeupperhalfofhousingclampovercomponentsin lower half. Join halves with two screws, Iockwashers,andnuts.Whenproperlyaligned,tighten screws.

12. Hold housing in a soft-jawed vise.

13. Slidespringoverpiston.Pushpistonintohousing.Holdcylindercapagainstbackofpistonandpushboth into housing until retainer can be installed.

14. Screwretainercapontocylindercapandtighten.

15.ApplyVibra-Tite®topistonthreads.Holdwedgeinpositioninhousing.Insert3/16”hexkeythroughbackofcap,andscrewpistonontowedge.NOTE: Apply NEVER-SEEZ® and MOLYKOTE® 106 to contact surfaces between wedge and lever. (Figure 9)

16.Holdleverinpositioninhousing,andpushpinthroughhousingandlever.UseTRUARCPliers#0200to install the retaining ring.

17.Positiontorsionspringinhousing,andtapsplitpinthroughhousingandspring.

18.Placebladeinhousinganduse1/8”hexkeytoinstallcapscrew.NOTE: Adjust tool lever before elbow is attached to tool. See Adjusting for Partially Swaged Collars.

19. Screw in elbow after adjusting lever. ApplyParkerThreadmate®, Loctite® 567, or Slic-Tite®topipethreads and tighten the connection. NOTE: Elbow can be omitted and hose installed directly into cylinder cap. This configuration provides advantages with some structural forms.

20. Install hose assembly into elbow. Install quick disconnects.

21. Topreventairbeingtrappedintool,causinglossofhydraulicpressure,fillhydraulichoseandtoolwithhydraulicfluidbeforescrewinghoseintoelbow.UseTEFLON®threadcompound.

Lever & Wedge LubricationFigure 9

CAUTION: Remove Elastomer Spring from Polyseal prior to assembly in tool.

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Subassembly Part Numbers and Drawings6CCX-QD, CCX-QD, & 8CCXS-QD

Part No. Description

128884 Piston Assemblycontains:Piston,(not available separately) and Polyseal

128878 EndCap&SwivelAssembly(Figure10)

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Figure 10

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Figure 1110CCX-QD & 12CCX-QD

Part No. Description

128970 Piston Assemblycontains:Piston,(not available separately) and Polyseal

128951 EndCap&SwivelAssembly(Figure11)

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Assembly Drawing 6CCX-QD

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Figure 16

19


Assembly Drawings

Air Trigger and Hose Assembly, 120346Figure 18

Switch and Electrical Cord Kit, 120245-2Figure 17

If needed for replacement, the Housing must be purchased separately.

20


Assembly Drawings (continued)

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Figure 19Hose and Switch Kit, 120347

Hydraulic Hoses and Air Trigger Assembly, 120348

21


Limited WarrantiesLimited Lifetime Warranty on BobTail® Tools:

HuckInternational,Inc.warrantstotheoriginalpurchaserthat its BobTail® installation tools manufactured after 12/1/2016 shall be free from defects in materials and workmanshipforitsuseful lifetime. This warranty does notcoverspecialorder/non-standardproducts,orpartfailureduetonormalwear,toolabuseormisapplication,orusernon-compliancewiththeservicerequirementsandconditionsdetailedintheproductliterature.

Two Year Limited Warranty on Installation Tools:

Huck International, Inc. warrants that its installation tools and Powerig®hydraulicpowersourcesmanufacturedafter 12/1/2016 shall be free from defects in materials andworkmanshipforaperiodoftwoyearsfromdateofpurchasebytheenduser.Thiswarrantydoesnotcoverspecialorder/non-standardproducts,orpartfailureduetonormalwear,toolabuseormisapplication,orusernon-compliancewiththeservicerequirementsandconditionsdetailedintheproductliterature.

90 Day Limited Warranty on Nose Assemblies and Accessories:

Huck International, Inc. warrants that its nose assemblies and accessories shall be free from defects in materials andworkmanshipforaperiodof90daysfromdateofpurchasebytheenduser.Thiswarrantydoesnotcoverspecialclearancenoses,orspecialorder/non-standardproduct,orpartfailureduetonormalwear,abuseormisapplication,orusernon-compliancewiththeservicerequirementsandconditionsdetailedintheproductliterature.

Useful lifetimeisdefinedastheperiodoverwhichtheproductisexpectedtolastphysically,uptothepointwhenreplacementisrequiredduetoeithernormalin-servicewear,oraspartofacompleteoverhaul.Determinationismadeonacase-bycasebasisuponreturnofpartstoHuckInternational, Inc. for evaluation.

Tooling, Part(s) and Other Items not manufactured by Huck:

HUCKmakesnowarrantywithrespecttothetooling,part(s),orotheritemsmanufacturedbythirdparties.HUCKexpresslydisclaimsanywarrantyexpressedorimplied,astothecondition,design,operation,merchantability,orfitnessforuseofanytool,part(s),orotheritemsthereofnotmanufacturedbyHUCK.HUCKshallnotbeliableforany loss or damage, directly or indirectly, arising from the useofsuchtooling,part(s),orotheritemsorbreachofwarranty or for any claim for incidental or consequential damages.

Huck shall not be liable for any loss or damage resulting fromdelaysornon-fulfillmentofordersowingtostrikes,fires,accidents,transportationcompaniesorforanyreasonorreasonsbeyondthecontroloftheHuckoritssuppliers.

Huck Installation Equipment:

Huck International, Inc. reserves the right to make changes inspecificationsanddesignandtodiscontinuemodelswithout notice.

HuckInstallationEquipmentshouldbeservicedbytrainedservice technicians only.

Alwaysgivetheserialnumberoftheequipmentwhencorrespondingororderingserviceparts.

CompleterepairfacilitiesaremaintainedbyHuckInternational,Inc.Pleasecontactoneoftheofficeslistedbelow.

EasternOneCorporateDriveKingston,NewYork12401-0250Telephone(845)331-7300FAX(845)334-7333

OutsideUSAandCanadaContact your nearest Huck International location (see reverse).

Inadditiontotheaboverepairfacilities,thereareAuthorizedToolServiceCenters(ATSC’s)locatedthroughouttheUnitedStates.Theseservicecentersofferrepairservices,spareparts,ServicePartsKits,ServiceToolKitsandNoseAssemblies.PleasecontactyourHuckRepresentativeorthenearestHuckInternationallocation(see reverse) for the ATSC in your area.

ArconicInc.(NYSE:ARNC)createsbreakthroughproductsthatshapeindustries.Workinginclosepartnershipwithourcustomers,wesolvecomplexengineeringchallengestotransformthewaywefly,drive,buildandpower.

Throughtheingenuityofourpeopleandcutting-edgeadvancedmanufacturing,wedelivertheseproductsataqualityandefficiencythatensurescustomersuccessandshareholder value.

Arconic Fastening Systems world-wide locations:

AMERICAS

Kingston Operations1CorporateDriveKingston,NY12401800-278-4825845-331-7300FAX:845-334-7333

Carson Operations900WatsoncenterRoadCarson, CA 90745800-421-1459310-830-8200FAX:310-830-1436

Waco OperationsPOBox81178001ImperialDriveWaco,TX76714-8117800-388-4825254-776-2000FAX:254-751-5259

Tucson Operations3724 East Columbia StreetTucson, AZ 85714800-234-4825520-519-7400

Acuña OperationsHidalgo #120Parque Industrial AmistadAcuña, Coahuila 26220MexicoFAX:525-515-1776

EUROPE

Telford OperationsUnitC,StaffordPark7Telford,ShropshireEngland TF3 3BQ+44 1952290011FAX:0952-290459

Us OperationsBP4 ClosD’Asseville95450UsparVignyFrance+33 1 30 27 95 00

AUSTRALIA

Melbourne Operations1508 Centre RoadClayton, Victoria Australia 3168+613 8545 33331300 363 049FAX:+61385453391

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Huck is Forever, For the Long Haul, The Future of Fastening Technology, The Future of Assembly Technology, The Future of Tooling Technology, and Tools of Productivity are trademarks of Huck International. Huck providestechnicalassistanceregardingtheuseandapplicationofHuckfastenersandtooling.

NOTICE:Theinformationcontainedinthispublicationisonlyforgeneralguidancewith

regardtopropertiesoftheproductsshownand/orthemeansforselectingsuchproducts,and is not intended to create any warranty, express,implied,orstatutory;allwarrantiesarecontainedonlyinHuck’swrittenquotations,acknowledgments,and/orpurchaseorders.Itisrecommendedthattheusersecurespecific,up-to-datedataandinformationregardingeachapplicationand/oruseofsuchproducts.

© 2018 Huck International, Inc. www.afshuck.net/us1 Corporate Drive, Kingston, NY 12401 • Tel: 800-431-3091 • Fax: 845-334-7333

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