Alcoa Huck 2024 Series User manual
04-24-2013
HK1077
INSTRUCTION MANUAL
2024 SERIES
PNEUDRAULIC INSTALLATION TOOLS
ALL MODELS
2024 series Tooling (HK1077) Alcoa Fastening Systems
2
January 29, 2014
PB618
THREADLOCKER RECOMMENDATION
Loctite®243 THREADLOCKER
TO REPLACE Vibra-Tite®IN
HUCK PNEUDRAULIC INSTALLATION TOOLS
Page 1 of 1
In order to ensure ease of assembly of back caps
and air pistons, among other components of HUCK
installation equipment, it is recommended that
wherever Vibra-Tite
®
has been mentioned in a HUCK
instruction manual or product bulletin procedure, the
product Loctite
®
243 Threadlocker be used instead.
This oil-tolerant, removable, medium-strength blue
threadlocker is designed for locking and sealing
threaded components. It can be applied smoothly
and will now be the HUCK recommended standard
for these applications. For best results, follow
manufacturer’s recommendations for use.
Loctite
®
243 Threadlocker is available for purchase
from HUCK in a .5 mL tube as part number 508567.
Locite is a registered trademark of Henkel Corporation, U.S.A.
Vibra-Tite is a registered trademark of ND Industries, Inc. USA.
For more informaƟon or to order, please contact your local distributor or call direct:
Alcoa Fastening Systems
1 Corporate Drive
Kingston, NY 12401
800-278-4825
PKG: 8452
GRP: 01 through 12, 15 through 19, & 21-22
This page is intentionally blank.
2024 series Tooling (HK1077) Alcoa Fastening Systems
3
CONTENTS
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRINCIPLE OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SERVICING THE TOOL
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
W
EEKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DISASSEMBLY
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
H
EAD/HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
P
INTAIL BOTTLE/VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ASSEMBLY
HEAD/HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
G
ENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
P
INTAIL BOTTLE/VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .11
FILL AND BLEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
MEASURING TOOL STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
ASSEMBLY DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
TROUBLESHOOTING & ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2024 series Tooling (HK1077) Alcoa Fastening Systems
4
I. GENERAL SAFETY RULES:
1. A half hour long hands-on training session with qualified personnel is
recommended before using Huck equipment.
2. Huck equipment must be maintained in a safe working condition at all
times. Tools and hoses should be inspected at the beginning of each
shift/day for damage or wear. Any repair should be done by a qualified
repairman trained on Huck procedures.
3. For multiple hazards, read and understand the safety instructions before
installing, operating, repairing, maintaining, changing accessories on,
or working near the assembly power tool. Failure to do so can result in
serious bodily injury.
4. Only qualified and trained operators should install, adjust or use the
assembly power tool.
5. Do not modify this assembly power tool. This can reduce effectiveness of
safety measures and increase operator risk.
6. Do not discard safety instructions; give them to the operator.
7. Do not use assembly power tool if it has been damaged.
8. Tools shall be inspected periodically to verify all ratings and markings
required, and listed in the manual, are legibly marked on the tool. The
employer/operator shall contact the manufacturer to obtain replacement
marking labels when necessary. Refer to assembly drawing and parts list
for replacement.
9. Tool is only to be used as stated in this manual. Any other use is
prohibited.
10.ReadMSDSSpecificationsbeforeservicingthetool.MSDSspecifications
are available from the product manufacturer or your Huck representative.
11.Only genuine Huck parts shall be used for replacements or spares. Use
of any other parts can result in tooling damage or personal injury.
12.Never remove any safety guards or pintail deflectors.
13.Never install a fastener in free air. Personal injury from fastener ejecting
may occur.
14.Where applicable, always clear spent pintail out of nose assembly before
installing the next fastener.
15.Check clearance between trigger and work piece to ensure there is
no pinch point when tool is activated. Remote triggers are available for
hydraulic tooling if pinch point is unavoidable.
16.Do not abuse tool by dropping or using it as a hammer. Never use
hydraulic or air lines as a handle or to bend or pry the tool. Reasonable
care of installation tools by operators is an important factor in maintaining
tool efficiency, eliminating downtime, and preventing an accident which
may cause severe personal injury.
17.Never place hands between nose assembly and work piece. Keep hands
clear from front of tool.
18.Tools with ejector rods should never be cycled with out nose assembly
installed.
19.When two piece lock bolts are being used always make sure the collar
orientation is correct. See fastener data sheet for correct positioning.
II. PROJECTILE HAZARDS:
1. Risk of whipping compressed air hose if tool is pneudraulic or pneumatic.
2. Disconnect the assembly power tool from energy source when changing
inserted tools or accessories.
3. Be aware that failure of the workpiece, accessories, or the inserted tool
itself can generate high velocity projectiles.
4. Always wear impact resistant eye protection during tool operation. The
grade of protection required should be assessed for each use.
5. The risk of others should also be assessed at this time.
6. Ensure that the workpiece is securely fixed.
7. Check that the means of protection from ejection of fastener or pintail is
in place and operative.
8. There is possibility of forcible ejection of pintails or spent mandrels from
front of tool.
III. OPERATING HAZARDS:
1. Use of tool can expose the operator’s hands to hazards including:
crushing, impacts, cuts, abrasions and heat. Wear suitable gloves to
protect hands.
2. Operators and maintenance personnel shall be physically able to handle
the bulk, weight and power of the tool.
3. Hold the tool correctly and be ready to counteract normal or sudden
movements with both hands available.
4. Maintain a balanced body position and secure footing.
5. Release trigger or stop start device in case of interruption of energy
supply.
6. Use only fluids and lubricants recommended by the manufacturer.
7. Avoid unsuitable postures, asit is likely for these not toallow counteracting
of normal or unexpected tool movement.
8. If the assembly power tool is fixed to a suspension device, make sure that
fixation is secure.
9. Beware of the risk of crushing or pinching if nose equipment is not fitted.
IV. REPETITIVE MOTION HAZARDS:
1. When using assembly power tool, the operator can experience discomfort
in the hands, arms, shoulders, neck or other parts of the body.
2. When using tool, the operator should adopt a comfortable posture while
maintaining a secure footing and avoid awkward or off balanced postures.
3. The operator should change posture during extended tasks to help avoid
discomfort and fatigue.
4. If the operator experiences symptoms such as persistent or recurring
discomfort,pain,throbbing,aching,tingling,numbness,burningsensations
or stiffness, these warnings should not be ignored. The operator should
tell the employer and consult a qualified health professional.
V. ACCESSORIES HAZARDS:
1. Disconnect tool from energy supply before changing inserted tool or
accessory.
2. Use only sizes and types of accessories and consumables that are
recommended. Do not use other types or sizes of accessories or
consumables.
VI. WORKPLACE HAZARDS:
1. Be aware of slippery surfaces caused by use of the tool and of trip
hazards caused by the air line or hydraulic hose.
2. Proceed with caution while in unfamiliar surroundings; there could be
hidden hazards such as electricity or other utility lines.
3. The assembly power tool is not intended for use in potentially explosive
environments.
4. Tool is not insulated against contact with electrical power.
5. Ensure there are no electrical cables, gas pipes, etc., which can cause a
hazard if damaged by use of the tool.
VII. NOISE HAZARDS:
1. Exposure to high noise levels can cause permanent, disabling hearing
loss and other problems such as tinnitus, therefore risk assessment and
the implementation of proper controls is essential.
2. Appropriate controls to reduce the risk may include actions such as
damping materials to prevent workpiece from ‘ringing’.
3. Use hearing protection in accordance with employer’s instructions and as
required by occupational health and safety regulations.
4. Operate and maintain tool as recommended in the instruction handbook
to prevent an unnecessary increase in the noise level.
5. Select, maintain and replace the consumable / inserted tool as
recommended to prevent an unnecessary increase in noise.
6. If the power tool has a silencer, always ensure that it is in place and in
good working order when the tool is being operated.
VIII. VIBRATION HAZARDS:
1. Exposure to vibration can cause disabling damage to the nerves and
blood supply to the hands and arms.
2. Wear warm clothing when working in cold conditions and keep hands
warm and dry.
3. If numbness, tingling, pain or whitening of the skin in the fingers or hands,
stop using the tool, tell your employer and consult a physician.
4. Support the weight of the tool in a stand, tensioner or balancer in order to
have a lighter grip on the tool.
IX. PNEUMATIC / PNEUDRAULIC TOOL SAFETY INSTRUCTIONS:
1. Air under pressure can cause severe injury.
2. Always shut off air supply, drain hose of air pressure and disconnect tool
from air supply when not in use, before changing accessories or when
making repairs.
3. Never direct air at yourself or anyone else.
4. Whipping hoses can cause severe injury, always check for damaged or
loose hoses and fittings.
5. Cold air should be directed away from hands.
6. Whenever universal twist couplings (claw couplings) are used, lock pins
shall be installed and whipcheck safety cables shall be used to safeguard
against possible hose to hose or hose to tool connection failure.
7. Do not exceed maximum air pressure stated on tool.
8. Never carry an air tool by the hose.
SAFETY INSTRUCTIONS
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.
Notes: are reminders of required procedures.
Bold, Italic type and underlining: emphasizes a specific instruction.
CAUTIONS: show conditions that will
damage equipment and or structure.
WARNINGS: Must be understood to avoid
severe personal injury.
2024 series Tooling (HK1077) Alcoa Fastening Systems
5
SPECIFICATIONS
5.413
137.49
12.568
319.23
8.910
226.31
.906
23.01
3.891
98.83
1.102
27.99
1.813
46.05
ø
4.355
110.62
ø
10°
10.32
262.3
1.258
31.95
2.477
62.92
ø
1.102
27.99
3.891
98.83
4.355
110.66
ø
.906
23.01
12.567
319.2
5.413
137.49
10°
1.813
46.05
ø
STROKE:
.850 in (2.16 cm)
WEIGHT:
5.5 lbs (2.5 kg)
MAX AIR PRESSURE:
90 psi (6.2 BAR)
MAX FLOW RATE:
8.5 scfm (241 l/m)
CAPACITY ( ):
3993 lbs (17.76 kN) @ 90 psi (6.2 BAR)
3549 lbs (15.79 kN) @ 80 psi (5.5 BAR)
MAX OPERATING TEMPERATURE:
125° F (52° C)
POWER SOURCE: 90psi MAX shop air
HYDRAULIC FLUID: ATF meeng DEXRON III, DEXRON IV,
MERCON, Allison C-4 or equivalent specificaons.
Fire resistant hydraulic fluid may also be used, and is
required to comply with OSHA regulaon 1926.302
paragraph (d): “the fluid used in hydraulic power tools
shall be fire resistant fluid approved under schedule 30 of
the US Bureau of Mines, Department of Interior, and shall
retain its operang characteriscs at the most extreme
temperatures to which it will be exposed.”
MODELS 2024 & 2024L MODELS 2024V & 2024LV
2024 series Tooling (HK1077) Alcoa Fastening Systems
6
PRINCIPLE OF OPERATION
PULL PISTON
SPRING
DAMPER VALVE
EX AUST AIR PISTON
ydraulic Oil
Air Pressure
Exhaust Air
YDRAULIC
PISTON
T ROTTLE VALVE
(PULL POSITION)
YDRAULIC
PISTON
T ROTTLE VALVE
(RETURN POSITION)
When the trigger is depressed the throle valve moves to
down posion, pressurized air is directed to the boom of
the air piston, causing the piston to move upward (Fig.1a).
The air above the piston is exhausted and directed through
the center of the throle valve and out the boom of the
tool.
As the hydraulic rod moves upward, a column of fluid is
forced into head, which moves the pull piston back. The
aached nose assembly moves with the pull piston to start
fastener installaon.
When fastener installaon is completed, the trigger is
released. Air pressure with the assistance of a spring
causes the throle valve to return to its up posion.
Pressurized air is re-directed to the top of the air piston
(Fig.1b), causing the air piston and hydraulic rod to move
downward.
The air from below the piston is exhausted through the
boom of the tool. Spring pressure returns the pull piston
to its home posion. The damper valve impedes oil flow at
pinbreak helping prevent “Tool Kick”.
Fig. 1a Fig. 1b
PREPARATION FOR USE
The Model 2024 Installaon Tool is shipped with a plasc
plug in the air inlet connector. The connector has 1/4-18
female pipe threads to accept the air hose fing. Quick
disconnect fings and 1/4” inside diameter air hose are
recommended. An air supply of 90 psi (6.2 bar) capable of
20 ³/s (.57 m³/s) must be available. Air supply should be
equipped with a filter-regulator-lubricator unit.
1. Remove plasc shipping plug from Air Inlet Connector
and put in a few drops of Automac Transmission Fluid,
DEXRON III, or equivalent.
2. Screw quick disconnect fing into Air Inlet Connector.
3.
Set air pressure on regulator to 90-100 psi.
4. Connect air hose to tool.
5. Cycle tool a few mes by depressing and releasing
trigger.
6. Disconnect air hose from tool.
7. Remove Retaining Nut.
8. Select proper Nose Assembly for fastener to be
installed.
9. Screw Collet Assembly (including lock collar and shim if
applicable) onto Spindle. (Wrench Tight)
10. Slide Anvil over Collet Assembly and into counterbore.
11. Slide Retaining Nut over Anvil and screw Nut onto
Head.
12. Connect air hose to tool and install fastener(s) in test
plate of proper thickness with proper size holes. Inspect
fastener(s).
NOTES:
1. Air quick disconnect fings and air hoses are not
available from Huck Internaonal, Inc.
2. On old style nose assemblies with lock collars, Vibra-
TITE should be used on collect threads, since there
is no staking hole provided on the 2024 pull piston.
Refer to nose assembly data sheets.
CAUTION: Do not use TEFLON tape on
threads. Use TEFLON in stick form only:
Huck P/N 503237
2024 series Tooling (HK1077) Alcoa Fastening Systems
7
SERVICING THE TOOL
GENERAL
1. The efficiency and life of any tool depends
upon proper maintenance. Regular inspection
and correction of minor problems will keep tool
operating efficiently and prevent downtime. The
tool should be serviced by personnel who are
thoroughly familiar with how it operates.
2. 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.
3. Proper hand tools, both standard and special,
must be available.
4. All parts must be handled carefully and
examined for damage or wear. Always replace
Seals, 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.
5. Service Parts Kit 2024KIT includes consumable parts
and should be available at all times. Other
components,
as experiece dictates, should also be available.
DAILY
1. If a Filter-Regulator-Lubricator unit is not being
used, uncouple air disconnects and put a few
drops of Automatic Transmission Fluid or light
oil into the air inlet of the tool. If the tool is in
continuous use, put a few drops of oil in every two
to three hours.
2. Bleed the air line to clear it of accumulated dirt or
water before connecting air hose to the tool.
3. Check all hoses and couplings for damage or air
leaks, tighten or replace if necessary.
4. Check the tool for damage or air/hydraulic leaks,
tighten or replace if necessary.
5. Check the nose assembly for tightness or
damage, tighten or replace if necessary.
6. Check stroke periodically, if stroke is short add
oil.
WEEKLY
1. Disassemble, clean, and reassemble nose
assemblies per applicable nose assembly
instructions.
2. Check the tool and all connecting parts for
damage or oil/air leaks, tighten or replace if
necessary.
as
experiece
dictates
,
should
also
be
available
.
WARNING: Inspect tool for damage or
wear before each use. Do not operate if
damaged or worn, as severe personal
injury may occur.
OPERATING INSTRUCTIONS
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 unl fastener is
installed and pintail breaks. Release trigger.
MAGNAGRIP® FASTENER INSTALLATION:
Place pin in work-hole and place collar over pin. See
WARNINGS. (If collar has only one tapered end, that
end MUST be out toward tool.) Hold pin in hole. Push
nose assembly onto pin protruding from collar unl anvil
touches collar. Press trigger and hold down unl collar is
swaged and pintail breaks. Release trigger.
WARNINGS:
Inspect tool for damage or wear before
each use. Do not operate if damaged or
worn as severe personal injury may occur.
Pulling on a pin (fastener) without a collar,
or with collar chamfer against workpiece,
may result in pin becoming a high speed
projectile when pin grooves are stripped
or pintail breaks off. Fatal or severe injury
is possible to anyone in the pins line of
flight. This includes pins that ricochet.
Broken pintails eject from deflector with
speed and force. Be sure pintail deflector
is directed safely away front operator
or the personnel in the area. Ejecting
pintails striking anyone may cause serious
personal injury. For Models 202B and
202V, 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.
CAUTION: Remove excessive gap from
between sheets for enough of the pintail
to stick out of the collar for all of the
jaw teeth to grip into the pintail grooves.
Jaws not fully gripping pintail grooves
will be stripped or broken.
2024 series Tooling (HK1077) Alcoa Fastening Systems
8
DISASSEMBLY INSTRUCTIONS 2024 ALL MODELS
For component identication and Parts list refer to Figures 2,
14, & 15.
NOTE: The following procedure is for complete
disassembly of tool. Disassemble only components
necessary to replace damaged O-rings, Quad rings,
Back-up rings, and worn or damaged components.
Always use soft jaw vice to avoid damage to tool.
1. Disconnect tool from air source.
2. Unscrew Retaining Nut (7) and remove nose assembly.
3. Unscrew Bleed Plug (55), from top of Handle/head.
Turn tool over and allow uid to drain into container
(Fig. 10 & 14).
4. 2024 & 2024L: Pull Pintail Deector (24) o End Cap
(21).
2024V & 2024LV: Please reference Disassembly of
Pintail Bottle and Vacuum System Procedure.
5. Remove Throttle Arm Pivot Screw (48) and Lever
Guard (73), and lift out Throttle Arm (53). Disconnect
ball end of Cable Assembly (2) from throttle arm.
6. Hold tool in vise with bottom up. (Fig. 2) Remove
Button Head Screws (40) with 1/8 hex key, then End
Cap (41) and Gasket (39). Remove Muer (42) from
end cap and Spring (49) from Throttle Valve (Fig.14).
7. Tap Cylinder Head (45) down with soft mallet (to take
pressure o ring), and remove Retaining Ring (38)
(Fig.2).
8. Screw Button Head Screws (40) back into Cylinder
Head. Carefully pry on screws to remove head.
Remove O-ring (46).
9. To remove air piston from cylinder, pull on Lock Nut
(43) with VISE-GRIPS. Remove Piston Quad Ring (47).
10. Remove Bumper (34) from Gland Assembly. Unscrew
Gland Assembly ( 25) with 1 3/8 socket wrench and
extension bar.
11. Remove SPIRO-LOX Retaining Ring (30) from gland
(26), pull out Spacer (29) and POLYSEAL (28). Then
remove O-rings (31 & 27), Quad Ring (33) & Back-up
Ring (32) (Fig. 14).
12. Lift cylinder (35) from handle/head (1) (Fig. 2).
13. Turn handle/head (1) over and drain uid into
container. Discard uid.
14. Pull Throttle Valve (52) out of air cylinder (35). Remove
O-Rings (50) (Fig. 14).
HEAD/HANDLE 2024 & 2024L:
(SeeFigures 3, 4 & 14)
15. Unscrew End Cap (21) and remove Spring (19), Spacer
(22) and Wiper Seal (23).
NOTE: For 2024V, reference DISASSEMBLY OF PINTAIL BOTTLE
AND VACUUM SYSTEM procedure.
35
Timing Pin
40
41
42
38
45
46
43, 44
37
47
34
36
25
39
1
Figure 2
10 R B (34) f Gl d A bl U
CAUTION: Care must be given not to
scratch piston rod or cylinder during
removal.
For component identication and Parts list refer to Figures 2
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.
2024 series Tooling (HK1077) Alcoa Fastening Systems
9
16. Thread POLYSEAL Insertion/removal Tool (121694-
2024), into rear of Handle/head. (Fig. 3)
17. Slide Spacer (123112-2 for 2024 or 123112-3 for 2024L)
onto piston.
18. Thread Piston Assembly Tool (123111-2 for 2024 or
123111-4 for 2024L) onto piston.
19. Push piston and front gland assemblies out the back of
the Handle/Head (1). Allow clearance, with stand-o,
for piston as it leaves the tool (Fig. 4).
20. Remove piston assembly tool and spacer from piston.
Rethread on the piston assembly tool only, then slide
the front gland assembly o the Piston (6) (Fig. 4).
21. Remove Piston Assembly Tool from Piston (6). Remove
POLYSEAL Insertion/removal Tool from rear of Head/
Handle (1).
23. Remove Retaining Ring (16), Washer (17) and
POLYSEAL (18) from piston.
NOTE: Inspect hydraulic piston for wear, scoring or
damage. Replace when necessary.
24. Unscrew Adapter (8) (Fig. 14).
25. Inspect all seals and parts.
26. 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.
PINTAIL BOTTLE/VACUUM SYSTEM
2024V & 2024LV
(See Figures 5, 6 & 15)
NOTE: The following steps are for disassembly of the
2025V and 2025LV models only. Please use these
steps in conjunction with the General and Head/
Handle disassembly sections of this manual.
1. By reaching through the window of Pintail Bottle (24)
remove Retaining Ring (62) and Washer (63) (Fig. 5).
2. Remove Pintail Bottle (24).
3. Disconnect tube from connector (54) (Fig. 15).
4. Remove Adapter (64) and Tube/ Slide Assembly (70).
5. Remove End Cap (21) and Spring (19) (Fig. 6).
6. Remove Spacer (22) and O-Ring (68) from spring side of
end cap.
7. From bottle side of end cap, remove Retaining Ring
(66), Wiper Housing (67), Wiper Seal (23), Washer (71)
and O-Ring (69).
8. Remove the O-Rings (65) from the inside of the Adapter
and Tube/Slide Assembly (70) (Fig 15).
1
8
PRESS
PISTON ASSY. TOOL
123111-2 (2024)
123111-4 (2024L)
SPACER
123112-2 (2024)
123112-3 (2024L)
POLYSEAL INSERTION TOOL
121694-2024
SUPPORT / STAND-OFF
Figure 3
6
18
17
16
910 14
15
12
11
Figure 4
62 & 63
24
21 70 64
Figure 5
DISASSEMBLY INSTRUCTIONS continued
19 22 68 21 69 71 23 67 66
Figure 6
2024 series Tooling (HK1077) Alcoa Fastening Systems
10
Head/handle 2024, 2024L
(Refer to Figures (7, 8 & 14)
NOTE:
Clean components with mineral spirits, or similar solvent;
inspect for wear/damage and replace as necessary.
Replace all seals of disassembled components. Use
O-rings, QUAD rings and Back-up rings in Service Parts
Kit, P/N 2024KIT or 2024VKIT Smear LUBRIPLATE
130AA or PARKER-O-LUBE on O-rings, QUAD rings,
Back-up rings and mating parts to ease assembly.
Assemble tool taking care not to damage O-rings, QUAD
rings, or Back-up rings.
1. If removed, position Cable Assembly (2) in Trigger
(5) slot and slide Dowel Pin (3) through holes in
trigger and cable assembly. Position assembled
trigger in handle and drive Pin (4) through holes in
handle and trigger (Fig. 14).
2. Screw Nose Adapter (8) into Head (1) and tighten.
3. Thread POLYSEAL Insertion/removal Tool (121694-
2024) into head.
4. Assemble piston (6), Polyseal (18) and retaining ring
(16) (Fig 7). Note Polyseal orientation.
5. Assemble front gland (15), O-ring (12), Back-up
ring (11), Polyseal (14) and Gland Cap (10). Note
Polyseal orientation.
6. Thread Piston Assembly Tool (123111-2 for 2024,
& 2024V) or (123111-4 for 2024L, & 2024LV) onto
Piston (6). Slide complete Gland Assembly and
Wiper Seal (9) onto Piston (6).
7. Install assembled components in gently from rear of
tool using a press as shown in (Fig. 8).
8. Remove Piston Assembly Tool (123111-2 or 123111-
4) and POLYSEAL Insertion / removal (121694-
2024) Tool.
9. Install Rear Wiper Seal (23) into End Cap (21) (Fig.
14).
10. Slide Spacer (22) and Spring (19) into End Cap
(21) and then thread End Cap assembly into rear
of Head. NOTE: For 2024V please reference
Assembly of Pintail Bottle and Vacuum System
procedure. (Refer to Figures 5, 6 & 10)
General:
(Refer to Figures 2 & 9)
11. Hold Head/Handle (1) inverted in vice (with soft
jaws). Place inverted Cylinder Assembly (35) on
base of handle. Timing pin maintains orientation.
12. Assemble Gland assembly (25) with new seals
(Fig. 9). Note orientation of polyseal. Apply Anti-
Seize Compound (Huck P/N 508183) to threads of
Gland Assembly. Screw gland into head/handle and
Torque to 50 ft. lbs. using 1 3/8 socket wrench.
13. Push Bumper (34) firmly over gland. NOTE: The
side of the bumper with two slots must face
toward the bottom of the tool.
ASSEMBLY INSTRUCTIONS 2024 ALL MODELS
LIP, THIS DIRECTION
16 17 18 6
PISTON ASSEMBLY (BULLET)
123111-2 (fo 2024 & 2024V) OR
123111-4 (fo 2024L & 2024LV)
11 12 15
14
10
9
LIP, THIS DIRECTION
FIG. 7
1
8
PRESS
POLYSEAL INSERTION TOOL
121694-2024
SUPPORT
FIG. 8
2024 series Tooling (HK1077) Alcoa Fastening Systems
11
General Assembly (continued):
(Refer to Figures 2 & 9)
14. Install Quad Ring (47) onto Air Piston (37).
15. Lubricate piston rod. Press assembled air piston/
rod into cylinder just enough to allow installation
of cylinder head (45).
16. Assemble O-Ring (46) onto Cylinder Head (45)
and then push Cylinder Head squarely into
cylinder taking care not to damage O-ring (46).
Install Retaining Ring (38). (Align screw holes
with muffler end cap)
17. Position Muffler (42) in center of cylinder head.
Position Gasket (39) on cylinder. ( Refer to Fig 2
& 9) Note direction of Lip
18. Carefully position Bottom Plate (41) on cylinder.
NOTE: Make sure that the muffler is properly
positioned in recess of Bottom Plate (41).
(Figures 2 & 14).
19. Secure the bottom plate with the three Button
Head Screws (40) using 1/8 hex key (Fig. 2).
20. Assembly O-Rings (50) on Throttle Valve (52).
(Fig. 14 Section CC)
21. Place the tool upright on a level surface, drop
Spring (49) into throttle valve bore in cylinder (35).
Push Throttle Valve into cylinder.
22. Place ball end of Throttle Cable (2) into end of
Throttle Arm (53), then slide Throttle Arm into slot
on Cylinder (Fig. 9).
23. Snap Lever Guard (73) in place, and install Pivot
Screw (48) in cylinder to retain throttle arm (53).
24. For 2024 & 2024L: Push Pintail Deflector (24)
onto End Cap (21).
For 2024V & 2024LV: Please reference
Disassembly of Pintail Bottle and Vacuum System
Procedure.
25. Tool is now completely assembled and needs to
be filled with oil. Please refer to the fill and bleed
section next.
Pintail Bottle/Vacuum 2024V & 2024LV:
(Refer to Figures 6 & 15 )
The following steps are for the assembly of the 2024V
& 2024LV models only. Please use these steps in
conjunction with the General and Head/Handle
disassembly sections of this manual.
1. Assemble Adapter and Tube/Side Assembly (70)
and new O-Rings (65).
2. From bottle side of End Cap (21) install O-Ring
(69),Washer(71),WiperSeal (23), WiperHousing
(67) and Retaining Ring (66) as shown in (Fig. 6).
3. From tool side of end cap install O-Ring (68),
Spacer (22) and Spring (19). (as shown in Fig. 6)
Screw entire assembly into head and tighten.
4. Assemble Tube/Slide Assembly and O-rings (65),
slide complete assembly onto End Cap (21) and
push tube into connector (54) (Fig.15).
5. Position Adapter (64) and pintail bottle (24) on
End Cap (21) (Fig. 5 & 15).
6. By reaching through the window of the Pintail
Bottle (24), install Washer (63) and Retaining
Ring (62) as shown in (Fig. 5).
ASSEMBLY INSTRUCTIONS continued
2024 series Tooling (HK1077) Alcoa Fastening Systems
12
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)
Preparation:
• Install air
regulator in airline
and set pressure
to 20-40 psi.
• Fill bleed bottle
almost full of
DEXRON III ATF
or equivalent.
Step 1
With fill port facing up, lay tool on it’s side, and remove
bleed plug (55) from bleed port.
Step 2
Connect tool to shop air set at 20 to 40 psi. If fluid is
present, hold tool over suitable container with fill port
facing into container. Cycle tool several times to drain
the old fluid, air and foam (Fig. 10)
Step 3
Screw fill bottle (120337) into fillport.
Step 4
Stand tool upright on bench. While triggering tool
slowly (20 - 30 cycles), bend fill bottle at right angles
to tool (Fig. 11) . Air bubbles will accumulate at
top of the bottle. When bubbles stop, cycling may be
discontinued.
Step 5
When trigger is released, pull piston returns to idle
position (full forward). Disconnect tool from airline.
Step 6
Lay tool on it’s side and remove fill bottle. Top off fluid
in fill port, install bleed plug and tighten.
Step 7
Connect airline to tool and measure the tools stroke,
refer to the Measuring Tool Stroke section. If stroke
is less than specified, remove bleed plug and top off
fluid. Reinstall bleed plug and recheck stroke.
Step 8
Increase air pressure to specifications. 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 and
measure again. Continue this process until stroke
meets minimum requirements.
CONTAINER
(DISCARD FLUID)
Figure 10
FILL POINT
120337 FILL BOTTLE
ASSEMBLY
Figure 9
Figure 11
FILL AND BLEED 2024 ALL MODELS
CAUTION: Refill using Automatic
Transmission Fluid DEXRON III or
equivalent for optimal performance.
WARNING: Avoid contact with hydraulic
fluid. Hydraulic fluid must be disposed
of in accordance with Federal, State and
Local Regulations. Please see MSDS for
Hydraulic fluid shipped with tool.
WARNING: WARNING: Air pressure
MUST be set to 20 to 40 psi to prevent
possible injury from high pressure
spray. If plug (55) is removed, fill bottle
must be in place before cycling tool.
CAUTION: All oil must be purged from
tool before Fill & Bleed process. Tool
stroke will be diminished if oil is aerated.
2024 series Tooling (HK1077) Alcoa Fastening Systems
13
MEASURING TOOL STROKE
Y
X
X
Y
Figure 12
Figure 13
2024 & 2024V
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
2024L & 2024LV
Step 1
Cycle Piston all the way forward and measure X.
Step 2
Cycle and hold piston back and measure Y.
Step 3
Stroke = X-Y
2024 series Tooling (HK1077) Alcoa Fastening Systems
14
ASSEMBLY DRAWING (Refer to Parts Lists on following pages)
HUCK INTL,INC
1 CORP. DR.
KINGSTON, N.Y.
12401 USA
SCFM L/M GPM
BARPSI
61*
60*
59*
M
A
X
PRESS
FLOW
HUCK 2024
S/N
54
55
56
A
A
73
20*
1*
2
3
4
5
6
78910 11 12
14 15
16 17 18
19 21
22 23
24
25
34
35*
36
37
38
39
40
41
42
43
44
45
46
47
48
SECTION A A
6
HUCK INTL,INC
1 CORP. DR.
KINGSTON, N.Y.
12401 USA
SCFM L/M GPM
BARPSI
61*
60*
59*
M
A
X
PRESS
FLOW
HUCK 2024
S/N
49
50
51
50
52
53
CC
(51) Swivel Assembly
57
SECTION C C
58
74
(25) Gland Assembly
26
27
28
29
30
31
32
33
*STICKER LOCATIONS
See special note about
stickers on Parts Lists
pages.
(2024)
(2024L style)
Timing Pin
72
Figure 14
2024 series Tooling (HK1077) Alcoa Fastening Systems
15
ASSEMBLY DRAWING (Refer to Parts Lists on following pages)
54
A
A
21 70 22 68 69 23 67 66
65 64 63 62
71
PARTIAL SECTION AA
24
6
FIG. 15
2024 series Tooling (HK1077) Alcoa Fastening Systems
16
PARTS LIST
ITEM Description 2024 2024L 2024V 2024LV QTY
1* Handle Assy 127748 128132 1
2 Cable Assy 116404-1 1
3 Dowel Pin 505496 1
4 Pin 500621 1
5 Trigger 124333-2 1
6Piston Assy (includes
Items 16, 17, & 18) 127743 127744 127744-2 127744-1 1
7 Retaining Nut 111795 1
8 Adapter 123761 1
9 Wiper Seal 505817 1
10 Gland Cap 122432 1
11 Back-up Ring 501110 1
12 O-Ring 500816 1
13 n/a n/a n/a
14 Polyseal 505818 1
15 Front Gland 123757 1
16 Retaining Ring 502827 1
17 Washer 127749 1
18 Polyseal 508188 1
19 Compression Spring 508187 1
20* WARNING Sticker 590240-1 1
21 End Cap 127742 125862 1
22 Spacer 507323 125866 1
23 Wiper Seal 507351 1
24 Pintail Deflector 124210 n/a 1
Pintail Bottle n/a 123772
25 Gland Assy 125742 1
26 Gland Housing 125740 1
27 O-Ring 500787 1
28 Polyseal 507447 1
29 Spacer 125741 1
30 Retaining Ring 506876 1
31 O-Ring 500785 1
32 Back-up Ring 501091 1
33 QUAD Ring 501075 1
34 Bumper 116408 1
35* Cylinder Assy 125733 1
36 Piston Rod 125743 1
37 Air Piston 125744 1
38 Retaining Ring 507445 1
39 Gasket 126941-4 1
40 Screw 504127 3 Continued on next page
* When replacing Cylinder (Item 35), Stickers (Items 59, 60, and 61)
must be ordered and placed in the locations shown in Figure 14.
When replacing Handle Assembly (Item 1), WARNING Sticker (Item 20)
must be ordered and placed in the location shown in Figure 14.
2024 series Tooling (HK1077) Alcoa Fastening Systems
17
PARTS LIST continued
ITEM Description 2024 2024L 2024V 2024LV QTY
41 Bottom Plate 128792 1
42 Muffler 115554-1 1
43 Lock Nut 505420 1
44 Washer 506493 1
45 Cylinder Head 125747 1
46 O-Ring 500871 1
47 QUAD Ring 501458 1
48 Pivot Screw 125118 1
49 Spring 116272 1
50 O-Ring 507396 3
51 Swivel Assy 507164 1
52 Throttle Valve 125562-1 1
53 Throttle Arm 125751 1
54 Plug Assy 506576 n/a 1
Tubing Connector n/a 506675
55 Plug 100309 1
56 O-Ring 505438 1
57 O-Ring 500779 2
58 O-Ring 500778 1
59* CE Sticker 590350 1
60*MAX Pressure and
Flow Sticker 590351 1
61*HUCK Address
Sticker 590347 1
62 Retaining Ring n/a 501007 1
63 Washer n/a 506628 1
64 Adapter n/a 123784 1
65 O-Ring n/a 500790 2
66 Retaining Ring n/a 502317 1
67 Wiper Housing n/a 125864 1
68 O-Ring n/a 500780 1
69 O-Ring n/a 500809 1
70 Tube and Slide Assy n/a 128044 1
71 Washer n/a 125865 1
72 Stop 120588 1
73 Lever Guard 126439 1
74 Retaining Ring 502274 1
* When replacing Cylinder (Item 35), Stickers (Items 59, 60, and 61)
must be ordered and placed in the locations shown in Figure 14.
When replacing Handle Assembly (Item 1), WARNING Sticker (Item 20)
must be ordered and placed in the location shown in Figure 14.
2024 series Tooling (HK1077) Alcoa Fastening Systems
18
TROUBLESHOOTING
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 as an aid in locating and correcting
malfunction.
1. Tool fails to operate when trigger is depressed.
a) Air line not connected
b) Throttle Valve O-rings (50) worn or damaged.
c) Throttle Valve Cable (2) is broken.
2. Tool does not complete fastener installation and
break pintail.
a) Air pressure too low
b) Air Piston Quad-ring (47) worn or damaged.
c) Tool is low on hydraulic fluid, refer to Fill and
Bleed section.
d) Air in hydraulic system, refer to Fill and Bleed
section.
3. Pintail stripped and/or swaged collar not ejected.
a) Check for broken or worn jaws in nose assembly,
refer to nose assembly data sheet.
b) Check for worn anvil, refer to nose data sheet.
4. Hydraulic fluid exhausts with air or leaks at base of
handle.
a) Worn or damaged Gland Assembly (25), inspect
Polyseal (28), O-rings (31 & 27),
Quad-ring (33) and Back-up ring (32) replace if
necessary.
5. Hydraulic fluid leaks at rear of Pull Piston (6)
a) Worn or damaged piston Polyseal (18), replace if
necessary.
6. Hydraulic fluid leaks at front of Pull Piston (6).
a) Worn or damaged Front Gland (15), inspect
Polyseal (14), O-ring (12) and Back-up Ring (11)
replace if necessary.
7. Pull Piston (6) will not return.
a) Throttle Valve (52) stuck: Lubricate O-rings (50).
b) Throttle Arm (53), Cable (2) or Trigger (5)
binding.
8. Air leaks at air Cylinder Head (45).
a). Worn or damaged O-ring (46) replace if
necessary.
Fill and Bleed Bottle (Fig. 9) - 120337
Stall Nut (2024 & 2024V) - 124090
Stall Nut (2024L & 2024LV ) - 125340
2024 & 2024V
Assembly Tool Kit - 123110-17
Includes: (Fig. 3)
Piston Assembly (Bullet) - 123111-2
Spacer - 123112-2
POLYSEAL Tool - 121694-2024
2024L & 2024LV
Assembly Tool Kit - 123110-17
Includes: (Fig. 3)
Piston Assembly (Bullet) - 123111-4
Spacer - 123112-3
POLYSEAL Tool - 121694-2024
Conversion Kit - 126190
(To convert 2024L to 2024LV)
Includes:
Pintail Collection Bottle - 123772
Tubing and Slide Assembly - 124245
Piston Assembly - 125738-3
End Cap Assembly - 125863
Conversion Kit - 126432
(To convert 2024 to 2024V)
Includes:
Pintail Collection Bottle - 123772
Tubing & Slide Assy - 124245
Piston Assy - 125738-2
End Cap Assembly - 125863
Vacuum Attach Adapter - 123784
Retaining Ring Ext - 501007
Flat Washer - 506628
Straight Connector - 506675
Service Kit (2024 & 2024L) - 2024KIT
Service Kit (2024LV & 2024V) - 2024VKIT
ACCESSORIES
This manual suits for next models
3
Table of contents
Other Alcoa Tools manuals
