Alcoa 2013 User manual

02-01-2005
HK978
INSTRUCTION MANUAL
2013 AND 2014
ALL MODELS
PNEUDRAULIC INSTALLATION TOOL

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2013 and 2014 Tooling Alcoa Fastening Systems
Huck Model 201 (family) Sound Level
SEL --- 75.7 dB (A)
peak value = 104.4 dB (C)
For an eight hour work day, installing 3000 typical Huck
fasteners will result in an equivalent noise level (Leq) of
65.9 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 201 (family) Vibration Level
For an eight hour work day, installing 3000 typical Huck
fasteners will result in an equivalent weighted RMS
vibration level (Aeq) of 12.25rn/s2.
To calculate the equivalent vibration level for other
quantities of fasteners in an eight hour period, use the
formula:
Equivalent Vibration Level, Aeq (rn/s2) = (n/480) x 1.96
where n = number of fasteners in eight hours, and 1.96
(m/s2) = Aeq for 60 seconds
EU Declaration of Conformity
Manufacturer:
Huck International Inc., Installation Systems Division, 85 Grand Street, Kingston, NY, 12401,
USA
Description of Machinery:
Model number 201 family of fastener installation tools
Relevant provisions complied with:
Council Directive related to Machinery, (89/392/EEC), (91/368/EEC), (93/44/EEC),
(93/68/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: November, 1995

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2013 and 2014 Tooling Alcoa Fastening Systems
SAFETY
This instruction manual must be read with particular
attention to the following safety guide lines, by
any person servicing or operating this tool.
1. Safety Glossary
WARNINGS - Must be understood
to avoid severe personal injury.
CAUTIONS - show conditions that will dam-
age equipment and or structure.
Notes - are reminders of required proce-
dures.
Bold, Italic type and underlining - empha-
sizes a specific instruction.
2. Huck equipment must be maintained in a safe
working condition at all times and inspected on a
regular basis for damage or wear. Any repair
should be done by a qualified repairman trained
on Huck procedures.
3. Repairman and Operator must read manual prior
to using equipment and understand any Warning
and Caution stickers/labels supplied with equip-
ment before connecting equipment to any pri-
mary power supply. As applicable, each of the
sections in this manual have specific safety and
other information.
4. See MSDS Specifications before servicing the
tool. MSDS Specifications are available from
you Huck representative or on-line at
www.huck.com. Click on Installation Systems
Division.
5. When repairing or operating Huck installation
equipment, always wear approved eye protec-
tion. Where applicable, refer to ANSI Z87.1 -
1989
6. Disconnect primary power source before doing
maintenance on Huck equipment.
7. If any equipment shows signs of damage, wear,
or leakage, do not connect it to the primary
power supply.
8. Make sure proper power source is used at all
times.
9. Never remove any safety guards or pintail
deflector.
10. Never install a fastener in free air. Personal
injury from fastener ejecting may occur.
11. When using an offset nose always clear spent
pintail out of nose assembly before installing the
next fastener.
12. If there is a pinch point between trigger and
work piece use remote trigger. (Remote trig-
gers are available for all tooling).
13. Do not abuse tool by dropping or using it as a
hammer. Never use hydraulic or air lines as a
handle. Reasonable care of installation tools by
operators is an important factor in maintaining
tool efficiency, eliminating downtime, and in pre-
venting an accident which may cause severe
personal injury.
14. Never place hands between nose assembly and
work piece.
15. Tools with ejector rods should never be cycled
with out nose assembly installed.
16. When two piece lock bolts are being used
always make sure the collar orientation is cor-
rect. See fastener data sheet of correct posi-
tioning.
!
Product complies with requirements
set forth by the relevant European
directives.
Read manual prior to using
equipment.
Eye protection required while
using this equipment.
Hearing protection required while
using this equipment.

2013 and 2014 Tooling Alcoa Fastening Systems
4
EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
SERVICING THE TOOL
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
Sub-assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Fill and Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-18
How to Measure Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
CONTENTS

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2013 and 2014 Tooling Alcoa Fastening Systems
The Model 2013 and 2014 series tools are light-
weight, high speed production tools designed to
install:
-04 through -06 diameter HUCK-CLINCH®
including oversize HUCK-CLINCH.
-04 through -05 diameter UNIMATIC® blind
rivets.
Any other blind fasteners having a pinbreak of
2650 lbs or less. The 2013V, with vacuum boost
selector switch ON, has two functions:
1. With tool in any position, vacuum holds
fastener firmly in nose assembly.
2. Vacuum expels broken pintail into pintail col
lector.
Pulling action of the pull piston is provided by a
pneumatic-hydraulic (pneudraulic) intensifier
system powered by 90 psi air pressure. The air
inlet is equipped with a connector with 1/4-18
female pipe threads to accept your air hose or
quick connect fitting The piston return stroke is
spring actuated
• Min. Stroke: .650
• Air Pressure: 90 psi
• Speed/Cycles: 20 per minute
• Air Consumption: 2.9 CFM
• Weight of 2013 and 2014: 4.4 lbs
• Weight of 2013B & 2013V: 4.7 lbs
• Min. Capacity: 2670 lbs ~ 90 psi
Fasteners installed: Consult your Huck representative or available FASTENER SELECTION
CHARTS.
Hydraulic Fluid: Automatic Transmission Fluid, DEXRON Ill, or equivalent.
DESCRIPTION
SPECIFICATIONS

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2013 and 2014 Tooling Alcoa Fastening Systems
Fig. 1.1
Outline Dimensions

PRINCIPLE OF OPERATION
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2013 and 2014 Tooling Alcoa Fastening Systems
When tool is connected to air supply, air pressure
holds throttle valve in the up position - - air pressure
is directed to the top of piston keeping it down.
Depressing trigger moves throttle valve to the down
position - - air is directed to the bottom of the piston
moving it upward. Air from above piston is exhausted
downward thru the throttle valve and exits the muffler
at bottom of the tool. The air piston rod is a hydraulic
piston which forces pressurized fluid into the cylinder
head - - pull piston moves rearward. The nose, which
is connected to the pull piston, will install the fastener
during the rearward piston movement.
When fastener installation is completed, and upon
trigger release, air pressure causes throttle valve to
return to its up position - - air flow reverses. The air
piston and rod move down to their starting position,
exhausting air from below the piston through the muf-
fler at bottom of tool. As rod moves downward and
hydraulic pressure is released from pull piston,
a spring behind pull piston returns it to its
starting position.
Fig. 2
Main Components

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2013 and 2014 Tooling Alcoa Fastening Systems
The 2013 and 2014 are shipped with a plastic
plug in the air inlet connector. Connector has
1/4-18 female pipe threads to accept the hose fit-
ting. Quick connect fittings and 1/4 inch inside
diameter air hose are recommended. An air
supply of 90-100 psi, capable of 2.9 CFM,
must be available. Air supply should be
equipped with a filter-regulator-lubricator unit.
1. Remove plastic plug from air inlet connector
and drop in a few drops of Automatic
Transmission Fluid, DEXRON Ill, or equiva-
lent.
2. Screw quick-connect fitting into air inlet
connector.
3. Set air pressure on regulator to 90-100 psi.
4. Attach optional air hose, part number
115436 (supplied with tool), to air inlet
connector.
5. Connect air hose to tool.
6. Cycle tool a few times by depressing and
releasing trigger.
7. Disconnect air hose from tool.
8. Remove retaining nut.
9. Select correct nose assembly from the
available SELECTION CHARTS or speak
with your Huck representative.
NOTE:
Quick disconnect fittings and air hoses are not
available from Huck.
PREPARATION FOR USE
!
WARNING
As applicable, do not use without
deflectors or pintail bottles.
If deflectors are removed or damaged,
separated pintails may eject forcibly
from rear of tool. Unshielded eyes,
especially, may be permanently injured.
Other severe injuries can be caused by
flying pintails. If there is any chance of
a projectile-like ejection, always point
rear of tool in a safe direction, or be
sure there is some structure that will
stop ejecting pintails.
WARNING
To avoid pinch points, be sure there is
adequate clearance for tool and opera-
tor’s hands before proceeding. Tool
moving toward structure may crush
hands or fingers between tool and
structure if clearance is limited.
!

OPERATING INSTRUCTIONS
NOTE: 2O13V is sold with the ribbed vacuum
control ON/OFF slide in the forward or OFF posi-
tion. See FIGURE 10 for slides location which is
shown in the ON (rear) position. While tool is not
being used, move slide to the OFF (forward) posi-
tion to prevent unnecessary air loss.
Blind Fastener Installation:
The fastener may be placed either in the work
hole or in the end of the nose assembly. In either
case, tool and nose assembly must be held
against work and at right angles to it. Depress
trigger and hold it depressed until fastener is
installed and pintail breaks. Release trigger.
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2013 and 2014 Tooling Alcoa Fastening Systems
Good Service Practice
Service Kits, 2013KIT, 2013BKIT, 2013VKIT, and
2014KIT include perishable parts and should be on
hand at all times. Other components, as experience
dictates, should also be kept for replacements.
ALWAYS REPLACE O-RINGS AND BACK-UP
RINGS WHEN TOOL IS DISASSEMBLED FOR
ANY REASON.
The efficiency and life of any tool depends upon
proper maintenance and good service practices.
Tool should be serviced by personnel who are
thoroughly familiar with it and how it operates.
A clean, well-lighted area should be available for
servicing the tool. Special care must be taken to
prevent contamination of pneumatic and hydraulic
systems. Proper 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. All parts
must be handled carefully and examined for dam-
age and/or wear. Components should be disas-
sembled and assembled in a straight line without
bending, cocking or undue force. Disassembly
and assembly procedures outlined in this manual
should be followed. If Huck recommended
procedures are not followed, the tool may be
damaged.
Rub SLIC-TITE TEFLON* thread compound, or
equivalent, on pipe plug threads and quick
connect fitting.
CAUTION: Do not use TEFLON tape on pipe
threads. Pipe threads may cause tape to shred
resulting in tool malfunction. (SLIC-TITE is
available in stick form, as 503237, from Huck.)
MAINTENANCE
!
WARNINGS
Inspect tool for damage before each use.
Do not operate if damaged as severe per-
sonal injury may occur.
Broken pintails eject from deflector with
speed and force - - be sure pintail deflec-
tor is directed safely away front operator
or the personnel in the area. Ejecting pin-
tails striking anyone may cause serious
personal injury. For Models 2013B and
2013V, pintail bottles must always be
used. Replace damaged pintail deflectors
and bottles as serious personal injury
may occur from pintails when using
these defective parts.

PREVENTIVE MAINTENANCE
MAINTENANCE (CONT.)
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2013 and 2014 Tooling Alcoa Fastening Systems
Smear LUBRIPLATE 130AA*, or equivalent lubricant,
on O-rings and mating surfaces to aid assembly and
to prevent damage to O-rings. (LUBRIPLATE 130AA
is available in a tube, as 502723, from Huck.)
Use VIBRA-TITE* or equivalent on Gland Housing
Assem., 116134-1, threads. Torque to 75-80 ft. lbs.
Apply LOCKTITE* #271 Adhesive/sealant to Locknut,
505420. (LOCKTITE is available from Huck, in a
tube, as 503657.) Torque to 25-30 ft. lbs.
* TEFLON is a trademark of E.l. DuPont de
Nemours & Co.
* LOCTITE is a trademark of Loctite Corp.
* TRUARC is a trademark of Waldes Kohinoor, Inc.
* VIBRA-TITE is a trademark of the Oakland
Corporation.
* LUBRIPLATE is a trademark of Fiske Brothers
Refining Co.
Standard Tools Available from Huck
1/8 hex key, 502294, used on button head screw,
504127.
5/32 hex key, 502295, used on socket cap screw,
123756.
(0400) TRUARC pliers, 502866, used on (N5100-l00)
retaining ring.
Tool Maintenance
The 2013 and 2014 series require a minimum amount
of maintenance. Regular inspection and correction of
minor problems will keep the tool operating efficiently
and prevent downtime.
Using filter-regulator-lubricator unit is highly recom-
mended for safe and reliable tool operation. If a filter-
regulator-lubricator unit is not being used in the air
supply: (1) remove hose fitting from air inlet connector
and drop in a few drops of automatic transmission fluid
or light oil (2) blow out air line to remove dirt and water
before connecting air hose to tool. At regular intervals,
depending upon use, replace all seals in tool. Service
Kits should be kept on hand. Inspect both hydraulic
pistons, and their piston rods for scored surfaces,
excessive wear or damage, and replace as necessary.
Always replace seals and back-up rings when tool is
disassembled for any reason to assure proper seal-
ing and tool function.
Nose Assembly Maintenance
Caution
Damaged jaw teeth, or debris packed between
teeth, will result in failure to install fastener or
improperly installed fastener.
Frequently cleaning the nose assembly is recommend-
ed. Remove nose assembly from tool and disassemble
- - see DISASSEMBLY Check components for any
signs of damage, e.g. cracks, scores and spring dam-
age. Check gripper teeth for damage. Remove any
debris packed between teeth with a sharp pointed
‘pick’. Periodically dip nose, while cycling tool, in min-
eral spirits, isopropyl alcohol or other suitable solvent,
to clean jaws and wash away metal chips and dirt.

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2013 and 2014 Tooling Alcoa Fastening Systems
DISASSEMBLY
Refer to MAINTENANCE: GOOD SERVICE
PRACTICE, FIGURES 4, 5, 6, 7, 8, 9, 10, 11,
and 12.
The following procedure is for complete disas-
sembly - - disassemble only subassemblies nec-
essary to check and replace damaged or worn
seals, wipers, back-up rings and other compo-
nents.
Always replace seals, wipers, and back-up
rings of disassembled sub-assemblies.
1. Disconnect tool from air source.
2. Unscrew Retaining Nut and remove nose
assembly.
3. Unscrew Bleed Plug, including O-ring, from
top of Handle/head. Turn tool over and allow
fluid to drain into container - - tool may be
cycled to clear tool more completely. Discard
fluid.
4. Pull Pintail Deflector off End Cap.
5. Remove Throttle Arm Pivot Screw and lift out
throttle arm. Disconnect ball end of Cable
Assembly from throttle arm.
6. Hold tool in vise with bottom up. Remove
Button Head Screws (3) with 1/8 hex key.
Remove End Cap and Gasket. Remove
Muffler from end cap. Remove Spring from
Throttle Valve.
7. To loosen Cylinder Head Retaining Ring in
Cylinder, tap Cylinder Head with mallet.
Remove Retaining Ring.
8. NOTE: Screw Button Head Screws back into
Cylinder Head. Carefully pull or pry on
screws to remove head.
9. To remove air piston from cylinder, pull on
Lock Nut with VISE-GRIP pliers.
Note: Air piston and rod should not be disas-
sembled and reassembled. If lock nut
loosens, apply LOCTITE #271 and tighten to
25-30 ft. lbs.
CAUTION
DO NOT SCRATCH, NICK OR DING PISTON
ROD. THIS WILL CAUSE PERMANENT
HYDRAULIC LEAKAGE.
10. Remove Bumper from Gland Assembly.
Unscrew gland with 1 3/8 socket wrench
and extension bar.
11. Remove SPIRO-LOX Retaining Ring from
gland. Pull out Spacer and POLYSEAL.
12. Lift cylinder from handle/head.
13. Turn handle/head over - - drain fluid into
container. Discard fluid.
14. Pull Throttle Valve out of cylinder.
Note: Service on Throttle Valve Bushings not
normally required.
!
WARNING
Air hose must be disconnected before:
• Removing or attaching nose
assembly.
• Cleaning tool and/or nose assem-
bly.
• Replacing worn or damaged tool
components.
Tool may be activated if not discon-
nected and cylinder is under pressure.
Fingers may be severely pinched/lac-
erated. Other severe personal injury
may result.

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2013 and 2014 Tooling Alcoa Fastening Systems
DISASSEMBLY (CONT.)
CAUTION
ONLY IF AIR LEAKAGE IS NOT COR-
RECTABLE WITH NEW THROTTLE VALVE
SEALS, BUSHINGS SHOULD BE REPLACED
IN CYLINDER.
15. Press out Lower Bushing and Upper
Bushing. Use square ended brass rods at
least six inches long. With proper diameter
rod, press out lower bushing first, and then,
press out upper bushing using a larger
diameter rod.
16. For 2013 and 2014: Place handle/head
securely in vise. Remove End Cap with
15/16” open end wrench. Extract Spring,
Washer and Wiper Seal.
For 2013B or 2013V: see Special
Disassembly Instructions on this page.
CAUTION
If Piston Seals and Gland Seals must be
reused, help prevent damaging them at
disassembly by installing OPTIONAL
POLYSEAL Insertion/removal Tool
(121694-202) in rear of Handle/head.
REMOVAL OF PISTON AND FRONT
GLAND - - see Fig. 12
17. Thread POLYSEAL Insertion/removal Tool,
121694-202, into Handle/head.
18. For 2013 Series Ony: Thread Piston
Assembly Tool, 123111-5 onto piston.
19. Push complete piston from front using
brass drift. Allow clearance, with stand-off,
for piston as it leaves tool.
20. Remove Piston Assembly Bullet, Spacer
and POLYSEAL Insertion/removal Tool.
NOTE: Inspect hydraulic piston for wear,
scoring or damage. Replace when neces-
sary.
21. Unscrew Adapter with wrench.
22. Inspect all seals and parts.
23. Remove trigger cable assembly by driving
pin with punch. Remove dowel pin to dis-
connect cable from trigger.
Special Disassembly Instructions
for 2013B and 2013V
1. Place handle/head securely in vise.Use 0100
TRUARC pliers, 502857, to remove retaining
ring - - reach through window of pintail bottle.
Remove washer.
2. Remove pintail bottle.
3. Remove bottle adapter and vacuum ON/OFF
slide.
4. Remove end cap assembly and spring.
5. Remove washer and O-ring from spring side
of end cap.
6. Remove retaining ring on bottle side of end
cap. Remove spacer, wiper seal, washer and
O-ring.
7. Remove O-rings from ON/OFF slide.

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2013 and 2014 Tooling Alcoa Fastening Systems
ASSEMBLY
See MAINTENANCE: GOOD SERVICE PRACTICE.
FIGURES 3, 4, 5, 6, 7, 8, 9, 10,11 and 13.
Clean all components with mineral spirits, and
inspect for wear or damage. Replace as necessary.
CAUTION
Always replace all seals, wipers and back-up
rings on/in disassembled components. These
parts wear from friction and deteriorate with age -
- replacement prevents potential leakage.
Use seals, wipers and back-up rings supplied in
SERVICE KIT, 2013KIT, 2013BKIT, 2012VKIT and
2014KIT -see NOTES. Smear LUBRIPLATE 130AA
or PARKER-O-LUBE on seals.
1. If Bushings have been removed from cylin
der:
Use an arbor press and apply LOCTITE #609,
(503377) on bushings before being pressed into
cylinder. Place chamfered end of Upper
Bushing In top of Cylinder. Carefully press
bushing squarely into cylinder. Repeat
procedure for Lower Bushing.
2. Assemble Gland Assembly - - see FIGURE
5.1.
NOTE: Cup of POLYSEAL must face toward
top of tool when installed in Gland.
Replace POLYSEAL, Spacer and SPIRO-Lox
Retaining Ring.
3. Install Adapter into cylinder handle/bead.
4. Thread POLYSEAL Insertion/removal Tool,
121694-202, into handle/head.
5. For 2013 Series Ony: Thread Piston
Assembly (bullet) Tool, 123111-5, onto piston
assembly.
6. Push front gland assembly onto piston, as
shown.
7. Slide wiper onto piston, as shown.
8. Push assembled components in gently from
rear of tool using a press, or a soft mallet and
wood or brass drift.
9. For 2013 Series Ony: Remove Piston
Assembly (bullet).
For 2013 and 2014: Remove POLYSEAL
Insertion/removal Tool.
10. For 2013 and 2014: Assemble Spring, Spacer,
Rear Wiper Seal and End Cap into handle/
head.
For 2013B or 2013V: reverse the disassembly
instructions in the Special Disassembly
Instructions for 2013B and 2013V;in the
Disassembly section.
11. See FIGURE 4 - - position Cable Assembly in
Trigger slot and push Dowel Pin through holes
in trigger and cable assembly. Position assem-
bled trigger in handle and drive Pin through
holes in handle and trigger.
12. Hold handle/head in vise with lower end point-
ing up. Turn cylinder bottom up, and position on
handle by lining up cylinder pin with handle
hole.
13. Apply VIBRATITE or equivalent to threads of
Gland Assembly. Screw gland into head/han-
dle. Using 1 3/8 socket wrench, tighten gland
to 75-80 ft. lbs.

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2013 and 2014 Tooling Alcoa Fastening Systems
ASSEMBLY (CONT.)
15. Lubricate piston rod. Press assembled
air piston/piston rod into cylinder just
enough to allow installation of cylinder
head.
16. Push Cylinder Head squarely into cylinder
taking care not to damage O-ring. Install
spiral Retaining Ring. Align screw holes
with muffler end cap.
17. Position Muffler in center of cylinder head.
Position Gasket on cylinder.
18. Carefully position Muffler End Cap on cylin-
der - - be certain that muffler is properly
positioned in recess of muffler end cap.
19. Muffler end cap is secured with three
Button head Screws - tighten with 1/8 hex
key.
20. Place tool upright on level surface. Drop
Spring into throttle valve bore in cylinder.
Push Throttle Valve into cylinder.
21. Place ball end of Throttle Cable in end of
Throttle Arm.
22. Slide Throttle Arm into slot on Cylinder.
23. Install Pivot Screw in cylinder to retain
throttle arm.
24. Follow FILL AND BLEED PROCEDURE
to fill tool - - see appropriate section.
25. Install Bleed Screw after FILL AND BLEED
PROCEDURE.
1 123775 Front Gland sub-assembly
includes:
(1) Front Gland Housing
500816 O-ring
501110 back-up ring
505818 POLY-SEAL
122432 Gland Cap
505817 wiper
2 123774-4 Piston sub-assembly includes:
(1) Piston
506160 POLY-SEAL
506654 flat washer
506653 external retaining ring
3 123777-2 Air Piston and Rod sub-
assembly includes:
(1)
501451 QUAD ring
111803-1 Piston Rod
506493 flat washer - - .38 ID; .751 OD
505420 self-Iocking nut - - .38-24 thin
SS
4 104293 Bleed Plug sub-assembly
includes:
(1) Bleed Plug
505438 O-ring
5 123778-1 Cylinder Head sub-assembly
includes:
(1) Cylinder Head
500864 O-ring
6 123779-1 Throttle Valve sub-assembly
includes:
(1) Throttle Valve
504408 O-ring
504407 O-ring
7 CAUTION
Install cups of POLY-SEALS positioned
as shown; position wipers as shown.
(1) Purchase sub-assembly when this part (1) is required.
Sub-assembly Part Numbers and Notes
Refer to illustrations

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2013 and 2014 Tooling Alcoa Fastening Systems
FILLING AND BLEEDING PROCEDURE
Equipment Required:
• Shop airline with 90 - 100 psi max.
• Air regulator
• Fill bottle, 120337, (supplied with tool).
• Large flat blade screwdriver
• Nose assembly or optional stall nut
• Fasteners (optional)
• Optional stall nut, 124090
Stall nut is used to load tool during bleeding
and for measuring stroke.
Preparation:
• Install air regulator in airline and set pressure to
20 - 40 psi.
2. Fill bleed bottle almost full of DEXRON III - - ATF
(automatic transmission fluid) - - see FIGURE 3.
Procedure to Fill Empty Tool (new or
rebuilt) - - as Applicable:
1. Attach the tool air source momentarily to seat air
piston at bottom of cylinder -- disconnect tool.
With fillport facing up, lay tool on its side.
2. With a screwdriver, remove bleed plug from
fillport.
3. Screw fill bottle into fillport in the head.
4. Set airline pressure to 20-40 psi and
Fig. 3
Fig. 3.1
WARNING
Air pressure MUST be set to 20 - 40 psi to
prevent possible injurious high pressure
spray. Never cycle tool without bleed plug
tightened, fill bottle tightened in tool, or
fillport held over a receptacle (see FIGURE
3.1). When not properly contained any
fluid present in tool will spray out. Severe
injury may result.
!

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2013 and 2014 Tooling Alcoa Fastening Systems
5. Stand tool upright on bench. While triggering tool
slowly (20 - 30 cycles), bend fill bottle at right
angles to tool - - see FIGURE 3.2. Air bubbles will
emerge from tool, When bubbles stop, cycling
may be discontinued.
6. When trigger is released, pull piston returns to
idle position (full forward). Disconnect tool from
airline.
7. Lay tool on its side. Remove fill bottle. Top off
fluid in fillport. Install bleed plug and tighten.
8. Connect airline to tool. There is a choice of two
procedures for measuring the stroke - - with and
without a stall-nut - - see appropriate section and
follow the selected procedure. If stroke is less
than specified, remove bleed plug and top off
fluid. Reinstall bleed plug.
9. Increase air pressure to specification. Install two
fasteners to check function and installation in a
single stroke, or cycle tool with stall-nut fully
threaded onto piston to load up tool. Measure
stroke again. Remove plug and top off fluid.
Reinstall plug and cycle again - - measure again.
Continue this process until stroke meets minimum
requirements.
Bleed Procedure for Partially Filled
Tool in Field Use - - as Applicable:
1. Disconnect tool from airline. With fillport facing
up, lay tool on its side.
2. Remove bleed plug from bleed port.
3. Hold tool over suitable container with fillport
facing into container.
4. Connect tool to airline. Cycle tool several times to
drain the old fluid, air and foam.
5. Screw fill bottle into fillport.
6. See WARNING above. With air pressure set at
20-40 psi, connect airline to tool.
Fig. 3.2
FILLING AND BLEEDING PROCEDURE (CONT.)
Fig. 3.3
WARNING
Air pressure MUST be set to 20 - 40 psi to
prevent possible injurious high pressure
spray. Never cycle tool without bleed plug
tightened, fill bottle tightened in the tool, or
the fillport held over a receptacle (see FIG-
URE 3.3). When not properly contained any
fluid present in tool will spray out. Severe
injury may result.
!

17
2013 and 2014 Tooling Alcoa Fastening Systems
FILLING AND BLEEDING PROCEDURE (CONT.)
7. Stand tool upright on bench. While actuating the
trigger slowly (20 - 30 cycles), bend fill bottle at
right angles to tool - - see FIGURE 3.4. Observe
that air bubbles emerge from tool. When bubbles
are no longer observed, cycling may be
discontinued.
Fig. 3.4 8. When trigger is released, pull piston returns to
idle position (full forward). Disconnect tool from
airline with piston full forward.
9. Lay tool on its side. Remove fill bottle. Top off
fluid in fillport. Install bleed plug and tighten with
screwdriver.
10. Connect airline to tool. There is a choice of two
procedures for measuring the stroke - - with and
without a stall-nut - - see appropriate section and
follow the selected procedure. If stroke is less
than specified, remove bleed plug and top off
fluid. Reinstall bleed plug.
11. Install two fasteners to check function and instal-
lation in a single stroke, or cycle tool with stall nut
fully threaded onto piston. Measure stroke again.
Remove plug and top off fluid. Reinstall plug and
cycle again - - measure again. Continue this
process until stroke meets minimum require-
ments.
SERVICE NOTES:

HOW TO MEASURE STROKE
18
2013 and 2014 Tooling Alcoa Fastening Systems
To measure stroke of tool without stall-
nut (nose assembly must be removed for this
procedure):
1. Disconnect tool from airline - - remove nose
from tool.
2. Reconnect tool to airline, with piston fully for
ward (end of RETURN stroke), measure and
record “Y” dimension - -see FIGURE 3.6.
3. Hold trigger depressed. Piston is now fully to
the rear and at end of PULL stroke. Measure
and record ‘X” dimension.
4. Subtract “X” dimension from “Y” dimension.
5. If stroke is less than 650, refer to appropriate
previous section. Follow filling and topping off
instructions.
Fig. 3.6
To measure stroke of tool with stall-nut
threaded onto piston (nose assembly must
be removed for this procedure):
1. Disconnect tool from airline - - remove
nose from tool.
2. Reconnect tool to airline. Cycle tool and hold
trigger depressed - - this keeps piston fully to
the rear and at end of PULL stroke. Thread
stall-nut back onto piston until it contacts
adapter bushing.
3. Release trigger. Stall-nut will move forward
with piston. See FIGURE 3.5 and measure “X”
dimension. This is the tool’s stroke.
Fig. 3.5
For the 2014 a Stroke Limiter Kit (p/n 126915) is shipped with the tool loose in bag.
4. If stroke is less than .650, refer to appropriate
previous section. Follow filling and topping off
instructions.
124090-3 Stall Nut (2013)
124090-4 Stall Nut (2014)

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2013 and 2014 Tooling Alcoa Fastening Systems
Fig. 4
2013 Series Head/Handle

20
2013 and 2014 Tooling Alcoa Fastening Systems
2014 Head/Handle
590160 STICKER
500621 PIN
500816 O-RING
501110 BU-RING
505817 WIPER
116404-1 CABLE ASSEMBLY
505496 DOWEL PIN
124333-1 TRIGGER
126661 ADAPTER
123757 RONT GLAND
123766 HANDLE ASSEMBLY
506654 WASHER
506160 POLYSEAL
506492 SPRING
126662 END CAP
126660 PISTON
122432 GLAND CAP
505818 POLYSEAL
506653 RETAINING RING
Fig. 4a
127313 Piston