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Huck 244 series User manual

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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