Huck 2024 User manual

04/12/2007
HK1077
INSTRUCTION MANUAL
2024 ALL MODELS
PNEUDRAULIC INSTALLATION TOOL

2
2024 Series Tooling Alcoa Fastening Systems
Test data to support the above information is on file at Alcoa Fastening Systems, Commercial Products Division, Kingston
Operations, Kingston, NY, USA. Vibration measurements are frequency weighted in accordance with ISO 8041 (1990).

3
2024 Series Tooling Alcoa Fastening Systems
C
CONTENTS
ONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SERVICING THE TOOL
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
WEEKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DISASSEMBLY
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
HEAD/HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
PINTAIL BOTTLE/VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
ASSEMBLY
HEAD/HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
PINTAIL BOTTLE/VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .13
FILL AND BLEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
MEASURING TOOL STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
ASSEMBLY DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19
TROUBLESHOOTING & ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4
2024 Series Tooling Alcoa Fastening Systems
This instruction manual must be read with
particular attention to the following safety
guidelines, by any person servicing or operating
this tool.
1Safety Glossary
WARNINGS - Must be understood
to avoid severe personal injury.
CAUTIONS - show conditions that will damage
equipment and/or structure.
Notes-are reminders of required procedures.
Bold, Italic type and underlining - emphasizes a
specific instruction.
2Huck 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.
3Repairman and Operator must read and understand
any Warning and Caution stickers/labels supplied
with equip-ment before connecting equipment to any
primary power supply - - as applicable, each of the
sections in this manual have specific safety, and
other information.
4When repairing or operating Huck installation
equipment always wear approved eye protection.
Where applicable, refer to ANSI Z87.1 - 1989
5Disconnect primary power source before doing
maintenance on Huck equipment.
6If any equipment shows signs of damage, wear or
leakage, do not connect it to the primary power
supply.
7Make sure proper power source is used at all times.
8Never remove any safety guards or pintail deflector.
9Never install a fastener in free air, personal injury
from fastener ejecting may occur.
10 Do not abuse tool by dropping or using it as a
hammer. Reasonable care of installation tools by
operators is an important factor in maintaining tool
efficiency, eliminating downtime and in preventing an
accident which may cause severe personal injury.
S
SAFETY
AFETY
Service Notes

5
2024 Series Tooling Alcoa Fastening Systems
T
TOOL
OOL S
SPECIFICATIONS
PECIFICATIONS
MODELS 2024 & 2024L
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°
• Stroke: .850 in
• Air Pressure: 90 psi
• Capacity: 3993 lbs @ 90 psi

6
2024 Series Tooling Alcoa Fastening Systems
T
TOOL
OOL S
SPECIFICATIONS
PECIFICATIONS
MODELS 2024V & 2024LV
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
• Air Pressure: 90 psi
• Capacity: 3993 lbs @ 90 psi

7
2024 Series Tooling Alcoa Fastening Systems
P
PRINCIPLE
RINCIPLE
OF
OF O
OPERATION
PERATION
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 throttle valve
moves to down position, pressurized air is directed
to the bottom 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
throttle valve and out the bottom of the tool. As
the hydraulic rod moves upward, a column of fluid
is forced into head, which moves the pull piston
back. The attached nose assembly moves with the
pull piston to start fastener installation.
When fastener installation is completed, the trigger
is released. Air pressure with the assistance of a
spring causes the throttle valve to return to its up
position. 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 bottom
of the tool. Spring pressure returns the pull piston
to its home position. The damper valve impedes
oil flow at pinbreak helping prevent “Tool Kick”.
Fig. 1(a) Fig. 1(b)

8
2024 Series Tooling Alcoa Fastening Systems
P
PREPARATION
REPARATION
FOR
FOR U
USE
SE
The Model 2024 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 - 100 psi capable of
20 CFM must be available. Air supply should be
equipped with a filter-regulator-lubricator unit.
1. Remove plastic shipping plug from Air Inlet
Connector and put in a few drops of Automatic
Transmission Fluid, DEXRON III, or equivalent.
2. Screw quick disconnect fitting into Air Inlet
Connector.
CAUTION: Do not use TEFLON tape on threads - -
use TEFLON in stick form only. (Huck P/N 503237)
3. Set air pressure on regulator to 90-100 psi.
4. Connect air hose to tool.
5. Cycle tool a few times by depressing and releasing
trigger.
6. Disconnect air hose from tool.
7. Remove Retaining Nut.
8. Select proper Nose Assembly from NOSE
ASSEMBLY SELECTION CHART 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 fittings and air hoses are not
available from Huck International, 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.
S
SERVICING
ERVICING
THE
THE
TOOL
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.
!
WARNING: Inspect tool for damage or wear
before each use. Do not operate if damaged
or worn, as severe personal injury may occur.

9
2024 Series Tooling Alcoa Fastening Systems
D
DISASSEMBLY
ISASSEMBLY I
INSTRUCTIONS
NSTRUCTIONS 2024
2024 ALL
ALL
MODELS
MODELS
For component identification and Parts list refer to
Figures 14 & 15.
General
(Refer to Figures 2 & 14)
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 fluid to drain into container
(Fig. 10 & 14).
4. For 2024 & 2024L: Pull Pintail Deflector (24) off End
Cap (21).
For 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. Remove
End Cap (41) and Gasket (39). Remove Muffler (42)
from end cap. Remove Spring (49) from Throttle Valve
(Fig.14).
7. Tap Cylinder Head (45) down with soft mallet (to take
pressure off 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). CAUTION: Care must be taken not to scratch
piston rod or cylinder during removal
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 fluid into
container. Discard fluid.
14. Pull Throttle Valve (52) out of air cylinder (35). Remove
O-Rings (50) (Fig. 14).
!
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.
35
Timing Pin
40
41
42
38
45
46
43, 44
37
47
34
36
25
39
1
FIG. 2

10
2024 Series Tooling Alcoa Fastening Systems
Head/handle 2024 & 2024L:
(Refer to Figures 3, 4 & 14)
15. Unscrew End Cap (21) and remove Spring (19),
Spacer (22) and Wiper Seal (23).
NOTE:
For 2024V please reference Disassembly of Pintail
Bottle and Vacuum System procedure.
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
2025L) 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-
off, 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 off 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.
24. 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 (Refer to Figures 5, 6 & 15)
NOTE:
The following steps are for the 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).
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
FIG. 3
6
18
17
16
910 14
15
12
11
FIG. 4
62 & 63
24
21 70 64
FIG. 5

11
2024 Series Tooling Alcoa Fastening Systems
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).
19 22
68
21 69 71 23 67 66
FIG. 6
____________________________________
____________________________________
S
SERVICE
ERVICE N
NOTES
OTES

12
2024 Series Tooling Alcoa Fastening Systems
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.
A
ASSEMBLY
SSEMBLY I
INSTRUCTIONS
NSTRUCTIONS 2024
2024 ALL
ALL
MODELS
MODELS
LIP, T IS DIRECTION
16 17 18 6
PISTON ASSEMBLY (BULLET)
123111-2 (for 2024 & 2024V) OR
123111-4 (for 2024L & 2024LV)
11 12 15
14
10
9
LIP, T IS DIRECTION
FIG. 7
1
8
PRESS
POLYSEAL INSERTION TOOL
121694-2024
SUPPORT
FIG. 8

13
2024 Series Tooling Alcoa Fastening Systems
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), Wiper Seal (23), Wiper Housing (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).

14
2024 Series Tooling Alcoa Fastening Systems
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.
Caution - Refill using Automatic Transmission Fluid
DEXRON III or equivalent for optimal performance.
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)
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 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.
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.
!
CONTAINER
(DISCARD FLUID)
FIG. 10
FILL POINT
120337 FILL BOTTLE
ASSEMBLY
FIG. 9
FIG. 11
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.
!
F
FILL
ILL
AND
AND B
BLEED
LEED 2024 A
2024 ALL
LL M
MODELS
ODELS

Y
X
15
2024 Series Tooling Alcoa Fastening Systems
M
MEASURING
EASURING T
TOOL
OOL S
STROKE
TROKE
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
X
Y
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
FIG. 12
FIG. 13

A
ASSEMBLY
SSEMBLY D
DRAWING
RAWING (Refer to Parts Lists on following pages)
16
2024 Series Tooling Alcoa Fastening Systems
1
2
3
4
5
6
7
8910 11 12 14 15 16 17 18 19 20 21
22
23
24
25
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
SECTION A-A
6
54
55
56
A
A
73
UCK INTL,INC
1 CORP. DR.
KINGSTON, N.Y.
12401 USA
SCFM L/M GPM
BARPSI
61
60
59
M
A
X
PRESS
FLOW
UCK 2024
S/N
(51) SWIVEL ASSEMBLY
57
SECTION C-C
58
(25) GLAND ASSEMBLY
26
27
28
29
30
31
32
33
(2024)
(2024L
style)
49
50
51
50
52
53
CC
Timing Pin
72
74
FIG. 14

17
2024 Series Tooling Alcoa Fastening Systems
54
A
A
21 70 22 68 69 23 67 66
65 64 63 62
71
PARTIAL SECTION AA
24
6
A
ASSEMBLY
SSEMBLY D
DRAWING
RAWING (Refer to Parts Lists on following pages)
FIG. 15

18
2024 Series Tooling Alcoa Fastening Systems
1 127748 127748 128132 128132 Handle Assembly 1
2 116404-1 116404-1 116404-1 116404-1 Cable Assembly 1
3 505496 505496 505496 505496 Dowel Pin 1
4 500621 500621 500621 500621 Pin 1
5 124333-2 124333-2 124333-2 124333-2 Trigger 1
6 127743 127744 127744-2 127744-1 Piston Assy 1
(Incl. Items 16,17 &18)
7 111795 111795 111795 111795 Retaining Nut 1
8 123761 123761 123761 123761 Adapter 1
9 505817 505817 505817 505817 Wiper Seal 1
10 122432 122432 122432 122432 Gland Cap 1
11 501110 501110 501110 501110 Back-Up Ring 1
12 500816 500816 500816 500816 O-Ring 1
14 505818 505818 505818 505818 Polyseal 1
15 123757 123757 123757 123757 Front Gland 1
16 502827 502827 502827 502827 Retaining Ring 1
17 127749 127749 127749 127749 Washer 1
18 508188 508188 508188 508188 Polyseal 1
19 508187 508187 508187 508187 Compression Spring 1
20 590240-1 590240-1 590240-1 590240-1 Sticker 1
21 127742 127742 125862 125862 End Cap 1
22 507323 507323 125866 125866 Spacer 1
23 507351 507351 507351 507351 Wiper Seal 1
24 124210 124210 123772 123772 Pintail Deflector/Bottle 1
25 125742 125742 125742 125742 Gland Assembly 1
26 125740 125740 125740 125740 Gland Housing 1
27 500787 500787 500787 500787 O-ring 1
28 507447 507447 507447 507447 Polyseal 1
29 125741 125741 125741 125741 Spacer 1
30 506876 506876 506876 506876 Retaining Ring 1
31 500785 500785 500785 500785 O-Ring 1
32 501091 501091 501091 501091 Back-Up Ring 1
33 501075 501075 501075 501075 Quad Ring 1
34 116408 116408 116408 116408 Bumper 1
35 125733 125733 125733 125733 Cylinder Assembly 1
P
PARTS
ARTS L
LIST
IST
ITEM PART NUMBER DESCRIPTION QTY
2024 2024V
2024L 2024LV

P
PARTS
ARTS L
LIST
IST
36 125743 125743 125743 125743 Piston, Rod 1
37 125744 125744 125744 125744 Piston, Air 1
38 507445 507445 507445 507445 Retaining Ring 1
39 126941-4 126941-4 126941-4 126941-4 Gasket 1
40 504127 504127 504127 504127 Screw 3
41 125750 125750 125750 125750 Bottom Plate 1
42 115554-1 115554-1 115554-1 115554-1 Muffler 1
43 505420 505420 505420 505420 Lock-nut 1
44 506493 506493 506493 506493 Washer 1
45 125747 125747 125747 125747 Cylinder Head 1
46 500871 500871 500871 500871 O-Ring 1
47 501458 501458 501458 501458 Quad Ring 1
48 125118 125118 125118 125118 Pivot Screw 1
49 116272 116272 116272 116272 Spring 1
50 507396 507396 507396 507396 O-Ring 3
51 507164 507164 507164 507164 Swivel Assembly 1
52 125562-1 125562-1 125562-1 125562-1 Throttle Valve 1
53 125751 125751 125751 125751 Throttle Arm 1
54 506576 506576 506675 506675 Plug Assy/Tubing Connector 1
55 100309 100309 100309 100309 Plug 1
56 505438 505438 505438 505438 O-Ring 1
57 500779 500779 500779 500779 O-Ring 2
58 500778 500778 500778 500778 O-Ring 1
59 590350 590350 590350 590350 Sticker 1
60 590351 590351 590351 590351 Sticker 1
61 590347 590347 590347 590347 Sticker 1
62 ---------- ---------- 501007 501007 Retaining Ring 1
63 ---------- ---------- 506628 506628 Washer 1
64 ---------- ---------- 123784 123784 Adapter 1
65 ---------- ---------- 500790 500790 O-Ring 2
66 ---------- ---------- 502317 502317 Retaining Ring 1
67 ---------- ---------- 125864 125864 Wiper Housing 1
68 ---------- ---------- 500780 500780 O-Ring 1
69 ---------- ---------- 500809 500809 O-Ring 1
70 ---------- ---------- 128044 128044 Tube and Slide Assembly 1
71 ---------- ---------- 125865 125865 Washer 1
72 120588 120588 120588 120588 Stop 1
73 126439 126439 126439 126439 Lever Guard 1
74 502274 502274 502274 502274 Retaining Ring 1
19
2024 Series Tooling Alcoa Fastening Systems
PART NUMBER DESCRIPTION
ITEM QTY
2024 2024V
2024L 2024LV

T
TROUBLESHOOTING
ROUBLESHOOTING
20
2024 Series Tooling Alcoa Fastening Systems
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
A
ACCESSORIES
CCESSORIES