Huck 244 series User manual

INSTRUCTION MANUAL
244/244OS
PNEUDRAULIC INSTALLATION TOOL
© Huck International, Inc. 1998 Patent Pending
HK 989 Rev. 04/30/2002
HUCK FASTENERS
HUCK FASTENERS
HUCK FASTENERS
HUCK FASTENERS
HUCK FASTENERS
HUCK FASTENERS
HUCK FASTENERS
HUCK FASTENERS

MODEL 244/244OS TOOL HUCK FASTENERS
EU Declaration of Conformity
Manufacturer:
Huck International, Inc., Installation Systems Division, 1 Corporate Drive, Kingston, NY,
12401, USA
Description of Machinery:
Model number 244 fastener installation tool
Relevant provisions complied with:
Council Directive related to Machinery, (89/392/EEC), (91/368/EEC), (93/44/EEC),
(93/68/EEC)
European Representative:
Rob Pattenden, 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: Henk Rosier
Position: Engineering Manager,
Installation Systems Division
Place: Kingston, New York, USA
Date: August, 1998
2
Huck Model 244/244OS Sound Power Level
The sound level of the 244/244OS tool cycling without
fastener is
Sound Exposure Level (SEL) =74.3 dB (A)
Peak Value = 94.2 dB (C)
The noise of the fastener being installed in structure is
considered process noise, not tool noise. Sound
measurements of simulated process noise are available
upon written request from Huck International in Kingston,
NY, USA.
Huck Model 244/244OS Vibration Level
For an eight hour work day, installing 3000 typical Huck
fasteners will result in an equivalent weighted RMS vibration
level (Aeq) of 2.04m/s2.
To calculate the equivalent vibration level for other quantities
of fasteners in an eight hour period, use the formula:
Equivalent Vibration Level, Aeq (m/s2) = (n/480) x 2.04
where n = number of fasteners in eight hours, and 2.04
(m/s2) = Aeq for 60 seconds.
Test data to support the above information is on file at Huck
International, Inc., Kingston, NY, USA. Vibration
measurements are frequency weighted in accordance with
ISO 8041 (1990).

MODEL 244/244OS TOOL HUCK FASTENERS
3
EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SERVICING THE TOOL
GENERAL, DAILY & WEEKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
FILL AND BLEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-15
ASSEMBLY DRAWING/PARTS LIST (244) . . . . . . . . . . . . . . . . . . . . .16-17
ASSEMBLY DRAWING/PARTS LIST (244OS) . . . . . . . . . . . . . . . . . .18-19
MEASURING/ADJUSTING TOOL STROKE (244OS) . . . . . . . . . . . . . . . .20
ATTACHING NOSE ASSEMBLY (244OS) . . . . . . . . . . . . . . . . . . . . . . . .21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
CONTENTS

MODEL 244/244OS TOOL HUCK FASTENERS
4
3.725
94.60
1.780
45.21
ø
.890
22.61
6.890
175.00
3.636
92.35
4.105
104.3
4.760
120.90
12.920
328.20
.945
24.00
1.890
48.00
ø
10°
• Stroke: .562 in
• Weight: 5 lbs 11oz
• Air Pressure: 90-100 psi
• Capacity: 4606 lbs @ 90 psi
• Speed/Cycles: 30 per minute
• Noise Level: 75 dBA @ 90 psi
TOOL SPECIFICATIONS
Model 244
INCHES
MM

MODEL 244/244OS TOOL HUCK FASTENERS
5
.945
24.00
.890
22.61
4.760
120.90
12.920
328.20
4.105
103.30
ø
3.725
94.60
1.780
45.21
ø
10°
3.886
98.70
4.497
114.21
4.625
117.50
3.636
92.35
1.890
48.00
ø
• Stroke: Adjustable 0 - .500 in
• Weight: 5 lbs 11oz
• Air Pressure: 90-100 psi
• Capacity: 4606 lbs @ 90 psi
• Speed/Cycles: 30 per minute
• Noise Level: 75 dBA @ 90 psi
TOOL SPECIFICATIONS
Model 244OS
INCHES
MM

MODEL 244/244OS TOOL HUCK FASTENERS
6
SAFETY
!
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 equipment
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.
This instruction manual must be read with particular attention to the
following safety guidelines, by any person servicing or operating
this tool.
MSDS and Safety Specifications are available on Hucks Tooling
Web-site www.hucktools.com. (Click on Safety Specifications)

MODEL 244/244OS TOOL HUCK FASTENERS
7
EXHAUST
HYDRAULIC
PISTON
AIR PISTON
RELIEF
AL E CHECK
AL E
PULL PISTON
THROTTLE
AL E
RESER OIR
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. The air above the piston is
exhausted and directed through the center of the
throttle valve and out the bottom of the tool . The
air piston has a rod and a hydraulic piston
attached. When the air piston rod moves upward,
a column of pressurized fluid is forced into head,
which moves the pull piston back. The attached
nose assembly moves with the pull piston spindle
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, causing the piston to move
downward. The air from below the piston is
exhausted through bottom of tool. The rod and
hydraulic piston move downward; hydraulic
pressure is reversed and the pull piston is returned
forward. Return pressure relief valve protects tool
against pressure spikes. The reservoir replenishes
hydraulic system as needed.
PRINCIPLE OF OPERATION

MODEL 244/244OS TOOL HUCK FASTENERS
8
The Model 244/244OS 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
(1) are recommended. An air supply of 90-100 psi capable
of 6.3 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. Attach optional Air Hose (Huck 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 and Stop. (244Only)
9. Select proper Nose Assembly from SELECTION
CHART for fastener to be installed.
10. 244OS Model:
Set stroke required for NoseAssembly selected. Refer
to Adjust Stroke section of this manual for adjustment
procedure (Fig 11).
11. 244 Model:
Attach NoseAssembly per NoseAssembly Data Sheet.
244OS Model:
Attach nose assembly per instructions on page 21
of this manual (Fig 12).
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 collet threads, since there is
no staking hole provided on the 244 pull piston. Refer
to nose assembly data sheets.
PREPARATION FOR USE
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 lit 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 244KIT includes consumable parts and
should be available at all times. Other components,
as experience 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 oil level in tool reservoir, replenish if necessary.
WEEKLY
1. Disassemble and clean nose assemblies and
reassemble per applicable NOSE ASSEMBLY DATA
SHEET.
2. Check the tool and all connecting parts for damage or
oil/air leaks, tighten or replace if necessary.
SERVICING THE TOOL
!
WARNING: Inspect tool for damage or wear
before each use. Do not operate if damaged or
worn, as severe personal injury may occur

MODEL 244/244OS TOOL HUCK FASTENERS
9
40
RESER OIR REMO ED
SPACER
73
LOCK OUT POSITION
FILL TOOL
112465
72
70
85
83
84
82
81
29
25
4x 69
75
76
78 77
1
22
21
15 9
71 (244)
93 (244OS)
71
FIG. 1
Model 244/244OS Disassembly/Assembly
For component identification and Parts list refer to
Figures ( 9 & 10 ).
DISASSEMBLY
(Refer to Figures 1-3 and 9 & 10)
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 air hose from tool.
2. Remove nose assembly. Follow instructions on Nose
Assembly Data sheet.
3. Insert Fill Tool, P/N 112465 through reservoir housing
and screw into Reservoir Plunger (73) locking it in the
out position (Fig1).
4. Unscrew Cap Screws (69) with 5/32 hex key. Carefully
lift Head straight up from Handle (1), remove Pull
GlandAssembly (29) and Return GlandAssembly (25)
from separated head and handle assemblies (Fig1).
5. Unscrew Plug (85) of return Pressure Relief Valve from
front of head. Remove Spring (84), valve Guide (82),
Sleeve (83) and Steel Ball (81). A small magnet is
helpful (Fig1).
6. Unscrew Bleed Plug (40). Hold over waste oil
container and release fill tool slowly (Fig1).
7. Unscrew Housing/Spacer Assembly (70) from head.
Remove two Springs (2x 71 for the 244 tool or 71 & 93
for the 244OS tool). Slide Reservoir Plunger (73) from
head. Remove spacer and Quad-Ring (72), a pick
may be used to remove the Quad-Ring (Fig1).
8. Unscrew Plug (78) of reservoir check valve from side
of head. Remove Spring (77), Check Valve Guide (76)
and Stainless Steel Ball (75) (Fig1).
9. 244 Model Only (Fig. 1 & 9)
Pintail Deflector (22) can be pulled off deflector tube at
rear of Piston.
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.
!

MODEL 244/244OS TOOL HUCK FASTENERS
10
10. 244 Model: (Fig. 1 & 9)
Unscrew End Cap (21) from Head, Plug & Seat
Assembly (15) with 1 9/16 open end wrench.
244OS Model: (Fig. 10)
Loosen and remove Locknut (92) from Piston Stop
(89). Unscrew Piston Stop (89) from End Cap (21),
then unscrew End Cap from Head, Plug & Seat
Assembly (15) with 1 9/16 open end wrench.
11. 244 Model: (Fig. 2a)
Place Spacer (123112-2) on piston and thread on
Piston Assembly Tool (123111-2) onto piston. Tap or
press piston assembly out of head.
NOTE: Piston will push out front and rear gland
assembly.
244OS Model: (Fig. 2b)
Place Spacer (123112-8) on piston and thread on
Piston Assembly Tool (123111-8) onto piston. Tap or
press piston assembly out of head.
NOTE: Piston will push out front and rear gland
assembly.
12. Remove Nose Adapter (9) from front of Head, Plug &
Seat Assembly (15). (Figs. 1 & 9) (Fig. 10 for 244OS
Model).
13. If Seat (74) is damaged, contact your Huck
representative. If Seat Assembly (80) is damaged, it
can be removed by using Seat Removal Tool (126136)
optionally available.
NOTE: Seats should not be reused. They should be
replaced.
14. With a small punch and hammer, drive Roll Pin (4) that
retains the Trigger (5) from the Handle (1). Remove
Trigger Pin (3). Remove ball cable end from Throttle
Arm (68) and pull Cable Assembly (2) out of Handle
(1). (Fig. 3)
15. Remove Pivot Screw (64) and Lever Guard (94) from
Throttle Arm (68). Remove Throttle Arm. Pull Throttle
Valve (67) out of cylinder. Remove Spring (65) (Fig3).
16. Remove Bleed Plug (40) from handle (Fig3).
17. Hold tool inverted in vice. Unscrew three Button Head
Screws (55) with 1/8 hex key (Fig3).
18. Remove Bottom Plate (56), Gasket (54) and Muffler
(57) (Fig3).
19. Remove Retaining Ring (62) from Cylinder Assembly
(51) (Fig3).
20. Install Screws (55) into Cylinder Head (60). Carefully
pry under screws to remove cylinder head.
21. Push air piston all the way down in cylinder, lay tool on
its side. Hold Locknut (58) with a 9/16 socket and
extension and with 7/64 hex key, remove piston Screw
(34).
22. Grip Locknut (58) under Air Piston with pliers and pull
piston and rod assembly from handle and cylinder
assembly.
CAUTION: Care must be taken not to scratch piston
rod or cylinder during removal.
24. Turn cylinder and handle upside down and secure in a
vise.
25. With a 1 3/8 socket and extension, remove Gland
Assembly (41). Handle and cylinder will now separate
(Fig3).
123112-8 SPACER
123111-8
PISTON ASSEMBLY
TOOL
Fig. 2a
Fig. 2a
Main Piston Tool Assy
Kit (123110-11)
Fig. 2b
Fig. 2b
Main Piston Tool Assy
Kit (123110-10)
SPACER
123112-2
PISTON ASSEMBLY
TOOL
123111-2
5
4
3
2
1
86
23
64
63
62 61 60 59 58 57 56 55
54
53
52
51
50
41
40
39
33
SECTION A-A
CC
A
A
66
65
66
67
68
34
94
FIG. 2
FIG. 3

MODEL 244/244OS TOOL HUCK FASTENERS
11
26. Push Piston Assembly (33) out of handle. Push out
from top to bottom.
CAUTION: A plastic or wooden drift must be used to
avoid damaging the handle bore.
27. Remove Swivel Assembly (86) from cylinder. Swivel
Assembly may be disassembled to replace seals (32 &
87) if necessary. (Fig. 9)
28. To remove Polyseal (43) from Gland Assembly (41),
Remove Retaining Ring (45) and Spacer (44). (Fig. 9)
ASSEMBLY
(See Figures 4 thru 7 and 9.)
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 244KIT. 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. Holding handle inverted in a vice, install Piston
Assembly (33) (with O-ring (35) and Back-up rings (36)
in place) in handle. *Press in from bottom of handle
taking care not to damage seals. (Fig. 4)
*Must be pressed in from bottom of handle to avoid
Damaging seals.
2. Place Cylinder Assembly (51) on handle with Timing
Pin (50) positioned in matching hole. Assemble Gland
Assembly (41) (See Fig. 9). Screw complete Gland
assembly into handle. Torque to 75-80 ft. lbs. using a
1 3/8 socket wrench. (Fig 5)
3. Push Piston Rod (63) through Air Piston (61) from flat
side. Drop Washer (59) over thread and screw
Locknut (58) onto rod. Hold hex of rod with 9/16
wrench, and torque nut using 9/16 socket to 28 - 32 ft.
lbs. (Fig 5).
CAUTION: Do not scratch piston rod.
4. Push assembled Air Piston and Rod into Air Cylinder
and Gland Assembly (41) until it stops. Push Screw
(34) with o-ring in place through hydraulic Piston
Assembly (33) and screw into top of piston rod. Hold
Locknut (58) with 9/16 socket and extension and
torque Screw (34) using 7/64 hex key to 55 - 60 in. lbs.
5. Push Cylinder Head (60) with O-ring (53) in place
squarely into cylinder. Install Retaining Ring (62).
(Fig. 6)
33
35 36
34
38 37
63
61
59
58
51
50
41
1
52
FIG. 5
FIG. 4

MODEL 244/244OS TOOL HUCK FASTENERS
12
6. Hold handle in vise with bottom
facing up. Position Muffler (57) on
center of Cylinder Head (60),
Place Gasket (54) on Cylinder
Assembly (51), place Bottom
Plate (56) on top of Gasket and
secure with 3 Button Head
Screws (55) using 1/8 hex key.
(Fig. 6)
7. Turn tool upright. Drop Spring
(65) into Throttle valve hole in
cylinder. Push Throttle Valve (67)
with O-rings (66) in place into
cylinder. (Fig. 6)
8. Assemble Trigger (5), Cable
Assembly (2) and Trigger Pin (3)
together and slide cable into
Handle (1). Align hole in Trigger
and hole in handle ears and install
Roll Pin (4) with a hammer and
punch. (Fig. 6)
9. Slide Throttle Arm (68) onto ball
end of Throttle Cable. Swing arm
until other end fits over throttle
valve.Place Lever Guard (94) over
Throttle Arm and install Pivot
Screw (64) through Throttle Arm .
Tighten with 5/32 hex key.
10. Install Swivel Assembly (86) in
Cylinder Assembly (51). (Fig. 9)
11. If Air Hose 115436 was removed,
reinstall in swivel assembly.
12. If Seat Assembly (80) is being
replaced push in seat and seal
assembly using soft drift taking
care not to damage ball seat
surface. (Fig. 9)
13. Assemble hydraulic Piston (18)
with new seals (16,17). Lubricate
with LUBRIPLATE or PARKER
SUPER-O-LUBE. (Fig. 9)
14. Install NoseAdapter (9) on front of
head. (Use VIBRA-TITE Huck
P/N 505125 on threads). Torque
to 50-60 ft. lbs. (Fig. 7)
15. Assemble Front Gland (12) Gland
Cap (11) O-ring (14) Back-up Ring
(13) and Polyseal (6). Thread
Piston Assembly Tool 123111-2
(244), 123111-8 (244OS) onto
5
4
3
2
1
64
63
62
61 60 59 58 57 56
55
54
53
52
51
50
41
40
39
33
29
25
CC
A
A
SECTION A-A
66
65
66
67
68
94
Fig. 7a
Fig. 7b
SECTION SHOWING
POLYSEAL DIRECTION
123111-2
PISTON ASSEMBLY
TOOL
10
11 12
13 14
6
9
18
16
17 (2)
16 18
17 (2)
123111-8
PISTON ASSEMBLY
TOOL
9
11 12
13 14
6
244OS only
FIG. 6
FIG. 7

MODEL 244/244OS TOOL HUCK FASTENERS
13
Piston (18). Slide complete Front Gland Assembly and
(Wiper Seal (10) 244 only) over Piston Assembly Tool
onto Piston. (Fig. 7)
16. Press entire piston and gland assembly into head.
Remove Piston Assembly Tool from piston. (Fig. 7)
17. 244 Model: (Fig. 9)
Place Seals (20) and (24) on Rear Gland (19). Push
complete assembly into head and screw in End Cap
(21), and torque to 50 - 60 ft. lbs.
244OS Model: (Fig. 10)
Place seals (20 & 24) on Rear Gland (19). Push
complete assembly into head and screw in End Cap
(21), torque to 50 - 60 ft. lbs. Thread Stop (89) into
End Cap (21) two turns, thread Locknut (92) onto
Piston Stop (89) and leave loose. For adjustment,
refer to Measuring Tool Stroke section of this manual
(Page 20).
18. Install Quad-Ring (72) and Spacer. Slide Reservoir
Plunger (73) in. {244OS Model: Install Spring (93) first,
then Spring (71); 244 Model: Install two Springs (71)}.
Screw Housing/Spacer Assembly into head. (Fig. 1)
19. 244 Model Only (Fig. 1 & 9)
Push Pintail Deflector (22) onto rear of Piston (18).
20. Place O-ring (39) on Plug (40) and screw assembly into
Handle (1). (Fig. 6)
21. Install Pull (29) and Return (25) Gland Assemblies in
handle. Push head down on glands. Place tool in a vise
Head down and install 4 Screws (69) and torque to 170
inch pounds. (Fig. 6 & 9)
22. Tool is now completely assembled except for relief and
check valves. See fill and bleed procedure for
replacement of valve components.
FILL AND BLEED 244/244OS(Fig. 8)
Equipment Required:
- Shop airline with 90-100 psi max.
- Air regulator
- Fill Bottle 120337 (supplied with tool).
- Fill Tool Assy 112465 (244)
- Fill Tool Assy 112465 (244OS)
- Large flat blade screwdriver
- Stall Nut 124090 (244)
Preparation:
1. 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 Fig. 8.)
Refill tool only when red line on plunger drops below the
red line on the reservoir housing or when tool is rebuilt.
REFILL: AUTOMATIC TRANSMISSION FLUID DEXRON
III, OR EQUIVALENT.
Step 1
Screw Fill Tool P/N 112465 into Reservoir Plunger, pull
Plunger into Housing and lock Fill Tool in full forward
position by tilting handle (long side touching tool) and
locking in place.
Step 2
Remove Relief Valve and Check Valve plugs, guides,
springs and balls from ports in head. Reinstall Plug
(85)and sleeve (83) in head in Relief Valve port (front of
tool).
Step 3
244 Model (Fig. 8)
Screw retaining nut onto Head Assembly. Screw Stall Nut
onto Piston and tighten to ensure full thread engagement.
Back off retaining nut until it engages stall nut. Check
Piston location. Piston must be all the way forward and
locked with stall nut and retaining nut.
244OS Model (Fig. 8)
Loosen Locknut (92). Screw Piston Stop (89) in until it
pushes and holds the piston in the full forward position.
Piston must be all the way forward and locked in place with
Stop.
Step 4
Attach the tool air source momentarily to seat air piston at
bottom of cylinder - disconnect tool. With fill port facing up,
(check valve on side) lay tool on its side (See Fig. 8).
Step 5
Install fill bottle in head fill port (check Valve hole) (See
Fig. 8).
Step 6
Connect tool to shop air 20 to 40 psi. Cycle tool 20-30
times, watch for air bubbles escaping from the tool into
bottle. (You may rock the tool to free trapped air in the
tool.) Do not allow the air to re-enter the tool. When
cycling tool, always hold bottle up as shown in Figure 8 to
prevent drawing in air from empty part of bottle.
Step 7
When air bubbles no longer appear in bottle, remove fill
bottle while tool is lying on its side.
Step 8
Install the check valve Ball (75), Check Valve Guide (76)
and Spring (77). Replace the Plug (78).
WARNING: Air pressure MUST be set to 20 to
40 psi to prevent possible injury from high
pressure spray. If plug (78) is removed, fill
bottle must be in place before cycling tool.
!

MODEL 244/244OS TOOL HUCK FASTENERS
14
Step 9
Turn tool so front of head faces you and remove the relief
valve Plug (85) and install relief valve Ball (81), Guide
(82), Sleeve (83) and Spring (84). Replace the Plug (85).
Step 10
244 Model (Fig. 8)
Unlock Fill Tool and check Reservoir red line. At this
point cycle the tool the with Stall Nut attached and
retaining nut locked in the full forward position (“Dead
Stall”). Reservoir should not drop below the red line on
the reservoir housing.
244OS Model (Fig. 8)
Unlock Fill Tool and check Reservoir red line. At this
point cycle the tool with the Stop still holding the piston in
the full forward position (“Dead Stall”). Reservoir should
not drop below the red line on the reservoir housing.
Step 11
Re-lock the fill tool.Lay tool on its left side and remove
Plug (40). Top off reservoir by placing a few drops of oil
in hole and waiting for air bubbles to escape. Push a pin
or a scribe into hole to check for trapped air bubbles.
Replace plug.
Step 12
Unlock the fill tool and cycle tool as in step 10. Reservoir
may drop slightly. If so, repeat step 11 until when you
touch the fill tool handle, it has no pressure against it and
it drops out of the lock position, and the plunger does not
drop when tool is cycled. NOTE: This usually requires 3
to 4 times topping off.
Step 13
244 Model (Fig. 8)
Remove fill tool and stall nut. Install a nose assembly
and pull several fasteners to test function.
244OS Model (Fig. 8)
Remove fill tool. Adjust the tools stroke for the Nose
Assembly being used by threading out Piston Stop (89).
Refer to Measuring Tool Stroke section for the stroke
adjustment procedure.
!
WARNING - Failure to re-lock the fill tool will
result in oil being ejected from the head under
pressure during the topping off of the
reservoir. Severe personal injury may result.
---------------- SERVICE NOTES:----------------

MODEL 244/244OS TOOL HUCK FASTENERS
15
(CHECK AL E HOLE)
85
83
84
82
81
75
76
78 77
INSTALL FILL & BLEED
BOTTLE HERE
85
Model 244OS
LOCKNUT (92)
PISTON STOP (89)
Model 244
RED LINE INDICATOR
124090 STALL NUT RETAINING NUT
40
FILL TOOL 112465 IN
LOCK OUT POSITION
FILL TOOL 112465-1 IN
LOCK OUT POSITION
120337 FILL BOTTLE ASSY
INCLUDES:
120336 FILL BOTTLE
120004 CAP
FILL POINT
FIG. 8
FILL AND BLEED

MODEL 244/244OS TOOL HUCK FASTENERS
16
10
88
86 SWI EL ASSEMBLY
66
87
32
85
28 79 84 83 82 81 80 79 28 78 39 77
76
75
74
40
39
73
72
49
48
46
45
44
43
42
41
33
38 37
36 35
34
29
32
31
27
28
30
25
28
27
26
70
65
66
67
68
69
64
63
62
61 60 59 58 57 56
55
54
53
52
51
50
41
40
39
33
29
25
24
22
21
20
19
18
17
16
15
C C
A
A
SECTION C-C
GLAND ASSEMBLY,
RETURN
GLAND ASSEMBLY,
PULL
GLAND ASSEMBLY
PISTON ASSEMBLY
SECTION B-B
SECTION A-A
B
B
1
2
3
4
5
6
7
8
9
11 12 13 14
28
71 (2)
94
ASSEMBLY DRAWING 244
FIG. 9

MODEL 244/244OS TOOL HUCK FASTENERS
17
1 125550 Handle 1
2 116404-1 Cable Assembly 1
3 505496 Trigger Pin 1
4 500621 Roll Pin 1
5 124333-1 Trigger 1
6 505818 Polyseal 1
7 111795 Retaining Nut 1
8 120588 Stop 1
9 125537 Nose Adapter 1
10 505817 Wiper Seal 1
11 122432 Gland Cap 1
12 125538 Front Gland 1
13 501113 Back-Up Ring 1
14 500819 O-Ring 1
15 125535 Head, Plug, & SeatAssy 1
16 507401 O-Ring 1
17 501142 Back-Up Ring 2
18 125885 Hydraulic Piston 1
19 125543 Rear Gland 1
20 500820 O-Ring 1
21 125545 End Cap 1
22 124211 Pintail Deflector 1
23 -------------- --------------------------------- ---
24 507400 Polyseal 1
25 125555 Return Gland Assembly 1
26 125554 Gland Housing 1
27 500776 O-Ring 3
28 501082 Back-Up Ring 6
29 125553 Pull Gland Assembly 1
30 125552 Pull Gland Housing 1
31 501085 Back-Up Ring 1
32 500779 O-Ring 3
33 118865 Piston Assembly 1
34 117773 Screw 1
35 503768 O-Ring 1
36 501084 Back-Up Ring 2
37 117774 Piston 1
38 500773 O-Ring 1
39 505438 O-Ring 3
40 100309 Plug 2
41 125557 Gland Assembly 1
42 126312 Gland/O-ring Assembly 1
43 506611 Polyseal 1
44 123904 Spacer 1
45 505939 Retaining Ring 1
46 500812 O-Ring 1
47 -------------- --------------------------------- ----
48 501074 Quad-Ring 1
49 500786 O-Ring 1
50 505496 Timing Pin 1
51 125560 Cylinder Assembly 1
52 501456 Quad-Ring 1
53 500869 O-Ring 1
54 125724-1 Gasket 1
55 504127 Screw 3
56 116585-1 Bottom Plate 1
57 115554-1 Muffler 1
58 505420 Locknut 1
59 506493 Washer 1
60 111959-1 Cylinder Head 1
61 123753 Air Piston 1
62 506490 Retaining Ring 1
63 125561 Piston Rod 1
64 125118 Pivot Screw 1
65 116272 Spring 1
66 507396 O-Ring 3
67 125562 Throttle Valve 1
68 123754 Throttle Arm 1
69 500062 Screw 4
70 112403 Housing/SpacerAssembly 1
71 505864 Spring 2
72 501408 Quad-Ring 1
73 112405 Reservoir Plunger 1
74 111139 Seat 1
75 502929 Ball 1
76 111067 Check Valve Guide 1
77 100874 Spring 1
78 111068 Plug 1
79 505446 O-Ring 2
80 126134 Seat Assembly 1
81 502506 Ball 1
82 120128 Guide 1
83 120127 Sleeve 1
84 507403 Spring 1
85 114530 Plug 1
86 507164 Swivel Assembly 1
87 500778 O-Ring 1
88 502274 Retaining Ring 1
94 125117 Lever Guard 1
ITEM PART# DESCRIPTION QTY ITEM PART# DESCRIPTION QTY
PARTS LIST 244

MODEL 244/244OS TOOL HUCK FASTENERS
18
ASSEMBLY DRAWING 244OS
28
27
26
32
28
27
31
30
34
36
38
37
35
88
42
43
44
45
49
48
46 65
69
66
66
6867
90
91
6
5
4
3
2
1
64
63
51
50
40
39
33
29
25
24
70 71 72 73 39 40
74
75
15
13 14
12
11
916 17 18 19 21
B
B
SECTION A-A
SECTION B-B
33 PISTON ASSEMBLY
41 GLAND ASSEMBLY
29 PULL GLAND ASSEMBLY
25 RETURN GLAND ASSEMBLY
87
32
86 SWI EL ASSEMBLY
SECTION C-C
A
A
CC
92 89
95
85 28 79 84 83 82 81 80 28 79 28 78 39
77
76
20
62 61 60 59 58 57 56 55
54
53
52
41
17
93
94
FIG. 10

MODEL 244/244OS TOOL HUCK FASTENERS
19
1 125550 Handle 1
2 116404-1 Cable Assembly 1
3 505496 Trigger Pin 1
4 500621 Roll Pin 1
5 124333-1 Trigger 1
6 505818 Polyseal 1
7 -------------- --------------------------------- ----
8 -------------- --------------------------------- ----
9 125947 Nose Adapter 1
10 -------------- --------------------------------- ----
11 126323 Gland Cap/Bearing 1
12 126530 Front Gland 1
13 501113 Back-Up Ring 1
14 500819 O-Ring 1
15 125535 Head, Plug, & SeatAssy 1
16 507401 O-Ring 1
17 501142 Back-Up Ring 2
18 125946 Hydraulic Piston 1
19 125543 Rear Gland 1
20 500820 O-Ring 1
21 125948 End Cap 1
22 -------------- --------------------------------- ----
23 -------------- --------------------------------- ----
24 507400 Polyseal 1
25 125555 Return Gland Assembly 1
26 125554 Gland Housing 1
27 500776 O-Ring 3
28 501082 Back-Up Ring 6
29 125553 Pull Gland Assembly 1
30 125552 Pull Gland Housing 1
31 501085 Back-Up Ring 1
32 500779 O-Ring 3
33 118865 Piston Assembly 1
34 117773 Screw 1
35 503768 O-Ring 1
36 501084 Back-Up Ring 2
37 117774 Piston 1
38 500773 O-Ring 1
39 505438 O-Ring 3
40 100309 Plug 2
41 125557 Gland Assembly 1
42 126312 Gland/O-ring Assembly 1
43 506611 Polyseal 1
44 123904 Spacer 1
45 505939 Retaining Ring 1
46 500812 O-Ring 1
47 -------------- --------------------------------- ----
48 501074 Quad-Ring 1
49 500786 O-Ring 1
50 505496 Timing Pin 1
51 125560 Cylinder Assembly 1
52 501456 Quad-Ring 1
53 500869 O-Ring 1
54 125724-1 Gasket 1
55 504127 Screw 3
56 116585-1 Bottom Plate 1
57 115554-1 Muffler 1
58 505420 Locknut 1
59 506493 Washer 1
60 111959-1 Cylinder Head 1
61 123753 Air Piston 1
62 506490 Retaining Ring 1
63 125561 Piston Rod 1
64 125118 Pivot Screw 1
65 116272 Spring 1
66 507396 O-Ring 3
67 125562 Throttle Valve 1
68 123754 Throttle Arm 1
69 500062 Screw 4
70 112403-1 Housing/SpacerAssembly 1
71 505864 Spring 1
72 501408 Quad-Ring 1
73 112405 Reservoir Plunger 1
74 111139 Seat 1
75 502929 Ball 1
76 111067 Check Valve Guide 1
77 100874 Spring 1
78 111068 Plug 1
79 505446 O-Ring 2
80 126134 Seat Assembly 1
81 502506 Ball 1
82 120128 Guide 1
83 120127 Sleeve 1
84 507403 Spring 1
85 114530 Plug 1
86 507164 Swivel Assembly 1
87 500778 O-Ring 1
88 502274 Retaining Ring 1
89 125949 Piston Stop 1
90 125951 Rotational Stop 1
91 500102 Cap Screw 1
92 501071 Locknut 1
93 507602 Spring 1
94 125117 Lever Guard 1
95 500784 O-Ring 1
ITEM PART# DESCRIPTION QTY ITEM PART# DESCRIPTION QTY
PARTS LIST 244OS

MODEL 244/244OS TOOL HUCK FASTENERS
20
MEASURING/ADJUSTING TOOL STROKE (244OS)
A
B
18
9
89
92
21
FIG. 11
ADJUSTING STROKE
1. Measure distance "A" from face of Hydraulic Piston (18) to face of Nose Adapter (9).
This distance should be approximately equal to .247 inches.
2. Cycle tool and hold piston back by keeping the trigger depressed. Measure distance
"B" as above.
3. STROKE = A+B
4. Adjust Piston Stop (89) clockwise to reduce dimension "B" (decreasing stroke) and
counterclockwise to increase "B" (increasing stroke). Repeat step 2.
5. When desired stroke has been reached, hold Piston Stop (89) with a ¼" hex key and
with a ¾" open end wrench tighten Locknut (92) against End Cap (21).