INSTRUCTION MANUAL 2025 SERIES PNEUDRAULIC INSTALLATION TOOLS ALL MODELS 03-15-2012 HK1006
025 series Tooling (HK1006) Alcoa Fastening Systems 2
2025 series Tooling (HK1006) Alcoa Fastening Systems C ONTENTS EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2025 series Tooling (HK1006) Alcoa Fastening Systems S AFETY I NSTRUCTIONS 11. Make sure proper power source is used at all times. GLOSSARY OF TERMS AND SYMBOLS: - Product complies with requirements set forth by the relevant European directives. - READ MANUAL prior to using this equipment. - EYE PROTECTION IS REQUIRED while using this equipment. - HEARING PROTECTION IS REQUIRED while using this equipment. 12. Release tool trigger if power supply is interrupted. 13.
2025 series Tooling (HK1006) Alcoa Fastening Systems S PECIFICATIONS Models 2025, 2025L, 2025S & 2025SL 3.865 98.17 STROKE: .675 in (1.715 cm) ø WEIGHT: 2025 & 2025L: 5 lbs 12oz (2.608 kg) 2025S & 2025SL: 7 lbs 4 ozs. (3.289 kg) 1.102 27.98 MAX AIR PRESSURE: 90 psi (6.2 BAR) .906 23.02 8.366 212.51 MAX FLOW RATE: 8.5 scfm (241 l/m) CAPACITY: 5290 lbs (23.531 kN) @ 90 psi (6.2 BAR) 1.812 46.
2025 series Tooling (HK1006) Alcoa Fastening Systems S PECIFICATIONS Models 2025V & 2025LV STROKE: .675 in (1.715 cm) WEIGHT: 5 lbs 12oz (2.608 kg) ø 3.87 98.17 1.10 27.98 .91 23.02 10.18 258.67 MAX AIR PRESSURE: 90 psi (6.2 BAR) MAX FLOW RATE: 8.5 scfm (241 l/m) 1.81 46.02 1.240 31.5 10° CAPACITY: 5290 lbs (23.531 kN) @ 90 psi (6.2 BAR) SPEED/CYCLES: 30 per minute MAX OPERATING TEMPERATURE: 125° F (52° C) ø 2.480 62.99 POWER SOURCE: 90psi MAX shop air 12.54 318.
2025 series Tooling (HK1006) Alcoa Fastening Systems S PECIFICATIONS Models 2025B & 2025LB STROKE: .675 in (1.715 cm) WEIGHT: 5 lbs 12oz (2.608 kg) ø 3.87 98.17 1.81 46.02 MAX AIR PRESSURE: 90 psi (6.2 BAR) MAX FLOW RATE: 8.5 scfm (241 l/m) 1.10 27.98 CAPACITY: 5290 lbs (23.531 kN) @ 90 psi (6.2 BAR) .91 23.02 9.65 245.11 SPEED/CYCLES: 30 per minute MAX OPERATING TEMPERATURE: 125° F (52° C) 1.240 31.
2025 series Tooling (HK1006) Alcoa Fastening Systems P RINCIPLE OF O PERATION PULL PISTON SPRING DAMPER VALVE HYDRAULIC PISTON HYDRAULIC PISTON THROTTLE VALVE (RETURN POSITION) THROTTLE VALVE (PULL POSITION) Hydraulic Oil Air Pressure EXHAUST Exhaust Air AIR PISTON Fig. 1b Fig. 1a When the trigger is depressed the throttle valve moves to the down position. Pressurized air is directed to the bottom of the air piston, causing the piston to move upward (Fig.1a).
2025 series Tooling (HK1006) Alcoa Fastening Systems P REPARATION The Model 2025 Installation Tool is shipped with a plastic plug in the air inlet connector. The connector has 1/4-18 female pipe threads to accept the air hose fitting. Quick disconnect fittings and 1/4” inside diameter air hose are recommended. An air supply of 90 psi (6.2 bar) capable of 20 ft³/s (.57 m³/s) must be available. Air supply should be equipped with a filterregulator-lubricator unit. FOR U SE 7. Remove Retaining Nut. 8.
2025 series Tooling (HK1006) Alcoa Fastening Systems D ISASSEMBLY I NSTRUCTIONS 2025 WARNING: Be sure air hose is disconnected from tool before cleaning, or performing maintenance. Severe personal injury may occur if air hose is not disconnected. ALL MODELS 40 Figure 2 41 For component identification and Parts list refer to Figures 2, 14, & 15. NOTE: The following procedure is for complete disassembly of tool.
2025 series Tooling (HK1006) Alcoa Fastening Systems D ISASSEMBLY I NSTRUCTIONS 2025 Figure 3 PRESS ALL MODELS 23. Unscrew Adapter (8) (Fig. 14). 24. Inspect all seals and parts. 25. If frayed or broken, remove trigger Cable Assembly (2) by driving Pin (4) out with punch. Remove Dowel Pin (3) to disconnect cable from trigger.
2025 series Tooling (HK1006) Alcoa Fastening Systems A SSEMBLY I NSTRUCTIONS 2025 HEAD/HANDLE 2025, 2025B, 2025L & 2025LB (Refer to Figures (7, 8 & 14) ALL MODELS 6. Thread Piston Assembly Tool (123111-2 for 2025, 2025B & 2025V) or (123111-4 for 2025L,2025LB & 2025LV) onto Piston (6). Slide complete Gland Assembly and Wiper Seal (9) onto Piston (6). For models 2025S & 2025SL, follow procedures for 2025 & 2025L. 7. Install assembled components in gently from rear of tool using a press as shown in (Fig.
2025 series Tooling (HK1006) Alcoa Fastening Systems A SSEMBLY I NSTRUCTIONS 2025 13. Push Bumper (34) firmly over gland. NOTE: The side of the bumper with two slots must face toward the bottom of the tool. ALL MODELS PINTAIL BOTTLE/VACUUM 2025V & 2025LV: (Refer to Figures 6 & 15 ) The following steps are for the assembly of the 2025V & 2025LV models only. Please use these steps in conjunction with the General and Head/Handle disassembly sections of this manual. 14.
2025 series Tooling (HK1006) F ILL AND Alcoa Fastening Systems B LEED 2025 A LL M ODELS Equipment Required: - Shop airline with 90 - 100 psi max. - Air regulator - Fill bottle, 120337, (supplied with tool). - Large flat blade screwdriver - Optional Stall Nut 124090 or 125340 - Nose assembly - Fasteners (optional) CAUTION: All oil must be purged from tool before Fill & Bleed process. Tool stroke will be diminished if oil is aerated. Step 3 Screw fill bottle (120337) into fill port.
2025 series Tooling (HK1006) Alcoa Fastening Systems M EASURING T OOL S TROKE Figure 12 X Y 2025, 2025B, 2025S & 2025V Step 1 Cycle Piston all the way forward and measure X. Step 2 Cycle and hold piston back and measure Y. Step 3 Stroke = Y-X Figure 13 X Y 2025L, 2025LB, 2025SL & 2025LV Step 1 Cycle Piston all the way forward and measure X. Step 2 Cycle and hold piston back and measure Y.
2025 series Tooling (HK1006) Alcoa Fastening Systems A SSEMBLY D RAWING (Refer to Parts Lists on following pages) A 72 7 8 9 10 11 12 Figure 14 14 15 16 17 18 24 6 (2024L style) 6 (2024) 20** 74 56 22 23 5 4 55 54 21 19 3 2 25 1** Timing Pin 34 48 35* 73 36 A 37 58 74 45 47 46 38 57 (51) Swivel Assembly SECTION C-C 39 44 43 42 SECTION A-A 53 40 41 31 52 30 32 50 29 28 51 27 33 26 C C (25) Gland Assembly 50 M PRESS A X FLOW 49 59* 16 60* PSI SCFM BAR L/
2025 series Tooling (HK1006) A SSEMBLY D RAWING Alcoa Fastening Systems (Refer to Parts Lists on following pages) FIG.
2025 series Tooling (HK1006) Alcoa Fastening Systems P ARTS L IST ITEM Description 1** 2 3 4 5 6 Handle Assy Cable Assy Dowel Pin Pin Trigger 2025 2025L 2025B 2025LB 2025V 2025LV 2025S 2025SL 125736 124333-2 124333-1 126980 116404-1 505496 500621 124333-2 124333-2 125738-2 (2025V) 125738 (2025S) Piston Assy (includes 125738 (2025, 2025B) Items 16, 17, & 18) 125738-1 (2025L, 2025LB) 125738-3 (2025LV) 125738-1 (2025SL) 7 8 9 10 11 12 13 14 15 16 17 18 19 20** 21 22 23 Retaining Nut Adapter Wipe
2025 series Tooling (HK1006) P ARTS L IST (continued) ITEM Description 41 42 43 44 45 Bottom Plate Muffler Lock Nut Washer Cylinder Head 46 O-Ring Alcoa Fastening Systems 2025 2025L 2025B 2025LB 2025V 2025LV 2025S 2025SL 128792 115554-1 505420 506493 125747 128792 115554-1 505420 506493 125747 128792 115554-1 505420 506493 125747 500871 500871 500871 501458 125118 116272 507396 n/a 125562-1 125751 n/a 506675 501458 125118 116272 507396 507164 125562-1 125751 506576 n/a QTY 1 1 1 1 1 1 Q
25 series Tooling (HK1006) Alcoa Fastening Systems A CCESSORIES T ROUBLESHOOTING Always check out the simplest possible cause of a malfunction first. For example, an air hose not connected. Then proceed logically, eliminating each possible cause until the cause is located. Where possible, substitute known good parts for suspected bad parts. Use TROUBLESHOOTING CHART as an aid in locating and correcting malfunction. Fill and Bleed Bottle (Fig.
2025 series Tooling (HK1006) Alcoa Fastening Systems L IMITED W ARRANTIES TO THE TOOLING, PART(S) OR OTHER ITEMS MANUFACTURED BY THIRD PARTIES. HUCK EXPRESSLY DISCLAIMS ANY WARRANTY EXPRESSED OR IMPLIED, AS TO THE CONDITION, DESIGN, OPERATION, MERCHANTABILITY OR FITNESS FOR USE OF ANY TOOL, PART(S), OR OTHER ITEMS THEREOF NOT MANUFACTURED BY HUCK.
For the Long Haul™ 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.
