Huck 244 series User manual
244X 244OSX
InstructIon Manual
244 serIes
PneudraulIc InstallatIon tools
March 11, 2015
HK989
Makers of Huck®, Marson®, Recoil®
Brand Fasteners, Tools & Accessories
2
244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
244 series Pneudraulic Installation Tools (HK989)Alcoa Fastening Systems & Rings
3
EU DEclaration of conformity ...................... 2
SafEty ......................................... 4
SpEcificationS...................................5-6
principlE of opEration ............................. 7
maintEnancE ..................................... 7
prEparation for USE .............................. 8
opErating inStrUctionS ............................ 8
DiSaSSEmbly ...................................9-10
aSSEmbly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
fill anD blEED ................................13-14
aSSEmbly DrawingS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
partS liSt ..................................... 18
mEaSUring anD aDjUSting tool StrokE . . . . . . . . . . . . . . . 19
attaching noSE aSSEmbly ......................... 19
troUblEShooting ................................ 20
accESSoriES .................................... 20
4
244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
I. GENERAL SAFETY RULES:
1.Ahalfhourlonghands-ontrainingsessionwithqualiedpersonnelis
recommendedbeforeusingHuckequipment.
2.Huckequipmentmustbemaintainedinasafeworkingconditionatall
times.Toolsandhosesshouldbeinspectedatthebeginningofeach
shift/dayfordamageorwear.Anyrepairshouldbedonebyaqualied
repairmantrainedonHuckprocedures.
3.Formultiplehazards,readandunderstandthesafetyinstructionsbe-
foreinstalling,operating,repairing,maintaining,changingaccessories
on,orworkingneartheassemblypowertool.Failuretodosocanresult
in serious bodily injury.
4.Onlyqualiedandtrainedoperatorsshouldinstall,adjustorusethe
assemblypowertool.
5.Donotmodifythisassemblypowertool.Thiscanreduceeffectiveness
ofsafetymeasuresandincreaseoperatorrisk.
6.Donotdiscardsafetyinstructions;givethemtotheoperator.
7.Donotuseassemblypowertoolifithasbeendamaged.
8.Toolsshallbeinspectedperiodicallytoverifyallratingsandmarkings
required,andlistedinthemanual,arelegiblymarkedonthetool.The
employer/operatorshallcontactthemanufacturertoobtainreplacement
markinglabelswhennecessary.Refertoassemblydrawingandparts
listforreplacement.
9.Toolisonlytobeusedasstatedinthismanual.Anyotheruseispro-
hibited.
10.ReadMSDSSpecicationsbeforeservicingthetool.MSDSspeci-
cationsareavailablefromtheproductmanufactureroryourHuck
representative.
11.OnlygenuineHuckpartsshallbeusedforreplacementsorspares.
Useofanyotherpartscanresultintoolingdamageorpersonalinjury.
12.Neverremoveanysafetyguardsorpintaildeectors.
13.Neverinstallafastenerinfreeair.Personalinjuryfromfastenereject-
ing may occur.
14.Whereapplicable,alwaysclearspentpintailoutofnoseassembly
before installing the next fastener.
15.Checkclearancebetweentriggerandworkpiecetoensurethereisno
pinchpointwhentoolisactivated.Remotetriggersareavailablefor
hydraulictoolingifpinchpointisunavoidable.
16.Donotabusetoolbydroppingorusingitasahammer.Neveruse
hydraulicorairlinesasahandleortobendorprythetool.Reason-
ablecareofinstallationtoolsbyoperatorsisanimportantfactorin
maintainingtoolefciency,eliminatingdowntime,andpreventingan
accidentwhichmaycauseseverepersonalinjury.
17.Neverplacehandsbetweennoseassemblyandworkpiece.Keep
hands clear from front of tool.
18.Toolswithejectorrodsshouldneverbecycledwithoutnoseassembly
installed.
19.Whentwopiecelockboltsarebeingusedalwaysmakesurethecollar
orientationiscorrect.Seefastenerdatasheetforcorrectpositioning.
II. PROJECTILE HAZARDS:
1.Riskofwhippingcompressedairhoseiftoolispneudraulicorpneu-
matic.
2.Disconnecttheassemblypowertoolfromenergysourcewhenchang-
ing inserted tools or accessories.
3.Beawarethatfailureoftheworkpiece,accessories,ortheinsertedtool
itselfcangeneratehighvelocityprojectiles.
4.Alwayswearimpactresistanteyeprotectionduringtooloperation.The
gradeofprotectionrequiredshouldbeassessedforeachuse.
5. The risk of others should also be assessed at this time.
6.Ensurethattheworkpieceissecurelyxed.
7.Checkthatthemeansofprotectionfromejectionoffastenerorpintailis
inplaceandoperative.
8.Thereispossibilityofforcibleejectionofpintailsorspentmandrelsfrom
front of tool.
III. OPERATING HAZARDS:
1.Useoftoolcanexposetheoperator’shandstohazardsincluding:
crushing,impacts,cuts,abrasionsandheat.Wearsuitableglovesto
protecthands.
2.Operatorsandmaintenancepersonnelshallbephysicallyableto
handlethebulk,weightandpowerofthetool.
3. Hold the tool correctly and be ready to counteract normal or sudden
movementswithbothhandsavailable.
4.Maintainabalancedbodypositionandsecurefooting.
5.Releasetriggerorstopstartdeviceincaseofinterruptionofenergy
supply.
6.Useonlyuidsandlubricantsrecommendedbythemanufacturer.
7.Avoidunsuitablepostures,asitislikelyforthesenottoallowcounter-
actingofnormalorunexpectedtoolmovement.
8.Iftheassemblypowertoolisxedtoasuspensiondevice,makesure
thatxationissecure.
9.Bewareoftheriskofcrushingorpinchingifnoseequipmentisnott-
ted.
IV. REPETITIVE MOTION HAZARDS:
1.Whenusingassemblypowertool,theoperatorcanexperiencediscom-
fortinthehands,arms,shoulders,neckorotherpartsofthebody.
2.Whenusingtool,theoperatorshouldadoptacomfortableposture
whilemaintainingasecurefootingandavoidawkwardoroffbalanced
postures.
3.Theoperatorshouldchangepostureduringextendedtaskstohelp
avoiddiscomfortandfatigue.
4.Iftheoperatorexperiencessymptomssuchaspersistentorrecurring
discomfort,pain,throbbing,aching,tingling,numbness,burningsensa-
tionsorstiffness,thesewarningsshouldnotbeignored.Theoperator
shouldtelltheemployerandconsultaqualiedhealthprofessional.
V. ACCESSORIES HAZARDS:
1.Disconnecttoolfromenergysupplybeforechanginginsertedtoolor
accessory.
2.Useonlysizesandtypesofaccessoriesandconsumablesthatare
recommended.Donotuseothertypesorsizesofaccessoriesorcon-
sumables.
VI. WORKPLACE HAZARDS:
1.Beawareofslipperysurfacescausedbyuseofthetoolandoftrip
hazardscausedbytheairlineorhydraulichose.
2.Proceedwithcautionwhileinunfamiliarsurroundings;therecouldbe
hiddenhazardssuchaselectricityorotherutilitylines.
3.Theassemblypowertoolisnotintendedforuseinpotentiallyexplosive
environments.
4.Toolisnotinsulatedagainstcontactwithelectricalpower.
5.Ensuretherearenoelectricalcables,gaspipes,etc.,whichcancause
ahazardifdamagedbyuseofthetool.
VII. NOISE HAZARDS:
1.Exposuretohighnoiselevelscancausepermanent,disablinghearing
lossandotherproblemssuchastinnitus,thereforeriskassessment
andtheimplementationofpropercontrolsisessential.
2.Appropriatecontrolstoreducetheriskmayincludeactionssuchas
dampingmaterialstopreventworkpiecefrom‘ringing’.
3.Usehearingprotectioninaccordancewithemployer’sinstructionsand
asrequiredbyoccupationalhealthandsafetyregulations.
4.Operateandmaintaintoolasrecommendedintheinstructionhand-
booktopreventanunnecessaryincreaseinthenoiselevel.
5.Select,maintainandreplacetheconsumable/insertedtoolasrecom-
mendedtopreventanunnecessaryincreaseinnoise.
6.Ifthepowertoolhasasilencer,alwaysensurethatitisinplaceandin
goodworkingorderwhenthetoolisbeingoperated.
VIII. VIBRATION HAZARDS:
1.Exposuretovibrationcancausedisablingdamagetothenervesand
bloodsupplytothehandsandarms.
2.Wearwarmclothingwhenworkingincoldconditionsandkeephands
warm and dry.
3.Ifnumbness,tingling,painorwhiteningoftheskininthengersor
hands,stopusingthetool,tellyouremployerandconsultaphysician.
4.Supporttheweightofthetoolinastand,tensionerorbalancerinorder
tohavealightergriponthetool.
IX. PNEUMATIC / PNEUDRAULIC TOOL SAFETY INSTRUCTIONS:
1.Airunderpressurecancausesevereinjury.
2.Alwaysshutoffairsupply,drainhoseofairpressureanddisconnect
toolfromairsupplywhennotinuse,beforechangingaccessoriesor
whenmakingrepairs.
3.Neverdirectairatyourselforanyoneelse.
4.Whippinghosescancausesevereinjury,alwayscheckfordamagedor
loosehosesandttings.
5. Cold air should be directed away from hands.
6.Wheneveruniversaltwistcouplings(clawcouplings)areused,lockpins
shallbeinstalledandwhipchecksafetycablesshallbeusedtosafe-
guardagainstpossiblehosetohoseorhosetotoolconnectionfailure.
7.Donotexceedmaximumairpressurestatedontool.
8.Nevercarryanairtoolbythehose.
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 specic
instruction.
WARNINGS: Must be understood to avoid se-
vere personal injury.
CAUTIONS: Show conditions that will damage
equipment or structure.
244 series Pneudraulic Installation Tools (HK989)Alcoa Fastening Systems & Rings
5
INCHES
(cm)
Power Source: 90 psi shop air
Hydraulic Fluid: Hydraulic uid shall meet DEXRON
III, DEXRON VI, MERCON, Allison C-4 or equivalent
ATF specications.
Fire resistant uid may be used if it is an ester based
uid such as Quintolubric HFD or equivalent. Water
based uid shall NOT be used as serious damage to
equipment will occur.
• Stroke: .562 in (1.43 cm) at full load with losses
• Weight: 5 lbs 11 oz (2.58 kg)
• Max Air Pressure: 90 psi (6.2 BAR)
• Max Flow Rate: 6.3 scfm (178 L/m)
• Capacity: 4606 lbs (20.49 kN) @ 90 psi (6.2 BAR)
• Speed/Cycles: 30 per minute
• Max Operating Temp: 125°F (52°C)
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244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
Power Source: 90 psi shop air
Hydraulic Fluid: Hydraulic uid shall meet DEXRON
III, DEXRON VI, MERCON, Allison C-4 or equivalent
ATF specications.
Fire resistant uid may be used if it is an ester based
uid such as Quintolubric HFD or equivalent. Water
based uid shall NOT be used as serious damage to
equipment will occur.
• Stroke: Adjustable 0-.562 in (0-1.43 cm)
• Weight: 5 lbs 11 oz (2.58 kg)
• Max Air Pressure: 90 psi (6.2 BAR)
• Max Flow Rate: 6.3 scfm (178 L/m)
• Capacity: 4606 lbs (20.49 kN) @ 90 psi (6.2 BAR)
• Speed/Cycles: 30 per minute
• Max Operating Temp: 125°F (52°C)
INCHES
(cm)
244 series Pneudraulic Installation Tools (HK989)Alcoa Fastening Systems & Rings
7
PULL
RETURN
GENERAL
1. The efficiency and life of any tool depends upon proper mainte-
nance. 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 used for service. and 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
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 oil level in tool reservoir, replenish if necessary.
WEEKLY
1. Disassemble and clean nose assemblies and reassemble.
2. Check the tool and all connecting parts for damage or oil/air
leaks, tighten or replace if necessary.
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244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
The Model 244 series Installation Tools are shipped with a
plastic plug in the air inlet connector. The connector has
1/4-18 female pipe threads to accept the air hose tting.
Quick disconnect ttings and 1/4” inside diameter air hose
are recommended. An air supply of 90-100 psi capable of 6.3
CFM must be available. Air supply should be equipped with a
lter-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 tting into Air Inlet Connector.
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. (244X only)
9. Select proper Nose Assembly for fastener to be installed.
10. 244OSX Model:
Set stroke required for Nose Assembly selected. Refer
to Adjust Stroke section of this manual for adjustment
procedure (Fig 11).
11. 244X Model:
Attach Nose Assembly per Nose Assembly Data Sheet.
244OSX 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 ttings and air hoses are not
available from Huck International, Inc.
2 On old style nose assemblies with lock collars, Loctite®
243 threadlocker (Huck P/N 508567) should be used on
collet threads, since there is no staking hole provided on
the pull piston. Refer to nose assembly data sheets.
* Threadmate is a registered trademark of Parker Intangibles LLC
* TEFLON is a registered trademark of DuPont Corp.
* Loctite is a registered trademark of Henkel Corporation, U.S.A.
CAUTION: Do not use TEFLON®tape on
pipe threads. Pipe threads may cause tape
to shred resulting in tool malfunction.
(Threadmate™ is available from Huck in a
4oz. tube as part number 508517.)
LOCKBOLT® FASTENER INSTALLATION:
Place pin in work hole and place collar over pin. See
WARNING. (If Collar has only one tapered end, that end
must be out toward tool, not next to sheet.) Hold pin and
push nose assembly onto pin protruding through collar
until nose assembly anvil touches collar. Depress trigger
and hold depressed until collar is swaged and pintail
breaks. Release trigger and tool will go into return stroke.
The tool and nose assembly are ready for the next fastener
installation cycle.
BLIND FASTENER INSTALLATION:
Remove excess gap from between the sheets to
permit correct fastener installation. Fastener may be placed
in work hole or in end of nose assembly. See WARNING. In
either case, tool and nose assembly must be held against
work and at right angles to it. Depress trigger and hold
it depressed until fastener is installed and pintail breaks.
Release trigger and tool will go into its return stroke.
The tool and nose assembly are ready for next fastener
installation cycle.
READ ALL WARNINGS AND CAUTIONS PRIOR TO USING YOUR SYSTEM. Failure to understand
WARNINGS may cause serious personal injury. Failure to understand CAUTIONS may cause damage to
structure and Tool. Additional safety information can be found on page 4.
CAUTION: Remove excess gap from
between the sheets. This permits enough
pintail to emerge from collar for ALL jaw
teeth to engage with pintail. If ALL teeth
do not engage properly, jaws will be
stripped and/or damaged.
WARNING: Do not pull on a pin without a
collar. The pin will eject with velocity and
force when the pintail breaks off. This may
cause serious injury.
WARNING: Do not pull on a fastener’s pin
without rst placing fastener In a work piece.
The fastener will eject forcibly when the pintail
breaks off. This may cause serious Injury.
CAUTION: To avoid structural and Tool
damage, be sure enough clearance is allowed
for nose assembly at full stroke. Do not abuse
the tool by dropping it, using it as a hammer
or otherwise causing unnecessary wear and
tear. Reasonable care of installation tools by
operators is an Important factor in maintaining
tool efciency and reducing downtime.
244 series Pneudraulic Installation Tools (HK989)Alcoa Fastening Systems & Rings
9
(Refer to Figures 1-3, 9a/b & 10)
NOTE: The following procedure is for complete disassembly
of tool. Only disassemble the components necessary to
replace damaged O-rings, Quad-Rings, Back-up Rings, and
worn/damaged components. Always use soft jaw vice to
avoid damage to tool.
1. Disconnect air hose from tool.
2. Remove nose assembly.
3. Insert Fill Tool through reservoir housing and screw into
Reservoir Plunger, locking it in the out position (Fig1).
4. Unscrew 4 Cap Screws with 5/32 hex key. Carefully lift Head
straight up from Handle. Remove Pull and Return Gland
Assemblies from separated head / handle (Fig1).
5. Unscrew Relief Valve Plug. Remove Relief Valve Spring,
Guide, Sleeve and Steel Ball. A small magnet is helpful.
6. Unscrew Reservoir Fill Plug. Hold over waste oil container
and release ll tool slowly (Fig1).
7. Unscrew Reservoir Housing/Spacer Assembly. Remove
2 Springs between housing and plunger. Slide Reservoir
Plunger from head. Remove Spacer and Quad-Ring (a pick
may be used to remove the Quad-Ring).
8. Unscrew Check Valve Plug, Spring, Guide, and Stainless
Steel Ball (Fig1).
9. 244X only (Fig. 1, 9a, 10)
Pintail Deector can be pulled at rear of Tool.
10. 244X: (Fig. 1, 9a, 10)
Unscrew End Cap (21) from Head, Plug & Seat Assembly
(15) with 1 9/16 open end wrench.
244OSX: (Fig. 1, 9b, 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. (Fig2) Place spacer over front of piston and thread piston
Assembly Tool onto Piston. Tap or press piston assembly
out of head. NOTE: This action will also push out front
and rear gland assemblies.
12. Pushing the piston out of the tool causes rear
gland/sleeve assy (Item 19, Fig. 9a/b) to be pushed
out as well. Slide sleeve o of piston in order to
replace seals on piston and to replace O-ring (Item
103, Fig. 9a/b) inside cylinder head.
13. Remove Nose Adapter (9) from front of Head, Plug &
Seat Assembly (15). (Figs. 1, 9a/b & 10).
14. 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.
15. With a small punch and hammer, drive Roll Pin (4) that
retains the Trigger (5) from the Handle. Remove Trigger
Pin (3). Remove ball cable end from Throttle Arm (68) and
pull Cable Assembly (2) out of Handle. (Fig. 3)
16. 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).
FIG. 1
FIG. 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.
10
244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
17. Remove Bleed Plug (40) from handle (Fig3).
18. Hold tool inverted in vice. Unscrew three Button Head
Screws (55) with 1/8 hex key (Fig3).
19. Remove Bottom Plate (56), Gasket (54) and Muer (57)
(Fig3).
20. Remove Retaining Ring (62) from Cylinder Assembly (51)
(Fig3).
21. Install Screws (55) into Cylinder Head (60). Carefully pry
under screws to remove cylinder head.
22. 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).
23. Grip Locknut (58) under Air Piston with pliers and pull
piston and rod assembly from handle and cylinder
assembly.
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).
26. Push Piston Assembly (33) out of handle. Push out from
top to bottom.
27. To service handle sleeve and handle, use a blunt-tipped
punch to gently tap sleeve from top of handle through
the bottom. Inspect sleeve for damage or wear, and
replace if necessary. Service O-ring inside handle bore.
28. Remove Swivel Assembly (86) from cylinder. Swivel
Assembly may be disassembled to replace seals (32 &
87) if necessary. (Fig. 9)
29. To remove Polyseal (43) from Gland Assembly (41),
remove Retaining Ring (45) and Spacer (44). (Fig. 9a/b)
FIG. 3
CAUTION: Care must be given not to scratch
piston rod or cylinder during removal.
CAUTION: A plastic or wooden drift must be
used to avoid damaging the handle bore.
244 series Pneudraulic Installation Tools (HK989)Alcoa Fastening Systems & Rings
11
Clean components with mineral spirits or similar solvent.
inspect for wear or damage and replace as necessary.
Replace all seals of disassembled components, using the
O-rings, Quad-Rings and Back-up rings provided in Service
Kit 244KIT. Smear LUBRIPLATE 130AA on O-rings, Quad-
Rings, Back-up rings and mating parts to ease assembly.
Assemble tool without damaging seals.
LUBRIPLATE is a registered trademark of LUBRIPLATE Lubricants Company.
1. Install internal handle O-ring. Holding handle inverted in
a vice, Install internal timing pin. Align small slot in sleeve
with timing pin in handle and press in until seated. (Fig.
4)
2. With handle still inverted in a vice, install Intensier
Piston (37), with O-ring (35) and Back-up rings (36) in
place into handle. (Fig. 4)
NOTE: The Intensier piston must be pressed in from
bottom of handle to avoid damaging seals.
NOTE: Ensure intensier piston is correctly oriented
prior to installation, as shown in Fig. 4.
3. Place Cylinder Assembly (51) on handle with Timing
Pin (50) positioned in matching hole. Assemble Gland
Assembly (41) (Fig. 9a/b). Screw complete Gland
assembly into handle. Torque to 75-80 ft. lbs. using a 1
3/8 socket wrench. (Fig 5)
4. Push Piston Rod (63) through Air Piston (61) from at
side. Drop Washer (59) over thread and screw Locknut
(58) onto rod. Using 9/16 wrench and socket, hold rod
hex and torque nut using 9/16 socket to 28-32 ft. lbs.
(Fig 5).
5. Push assembled Air Piston and Rod into Air Cylinder and
Gland Assembly (41) until it stops. Apply Loctite® 243™
to threads of Screw (34), and press Screw, with O-ring
(38) 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.
Loctite is a registered trademark of Henkel Corporation.
6. Push Cylinder Head (60) with O-ring (53) in place squarely
into Cylinder. Install Retaining Ring (62). (Fig. 6)
7. Hold handle upside down in vise. Position Muer (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)
8. 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)
9. 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)
10. Slide Throttle Arm (68) onto ball end of Throttle Cable.
Swing arm until other end ts over throttle valve.Place
Lever Guard (94) over Throttle Arm and install Pivot
Screw (64) through Throttle Arm. Tighten with 5/32 hex
key.
continued
FIG. 5
Assembled
Intensifier Piston*
Timing Pin
Internal Handle O-ring
Sleeve
Handle
*
36
36
35
FIG. 4
CAUTION: Do NOT scratch piston rod.
12
244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
11. Install Swivel Assembly (86) in Cylinder Assembly
(51), and reattach air hose (if removed). (Fig. 9a/b)
12. If Seat Assembly (80) is being replaced, push seat
and seal assembly in using soft drift. Take 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. 9a/b)
14. Install Nose Adapter (9) on front of head. Apply
Loctite® 243™ threadlocker to threads per
manufacturer’s instructions. Torque to 50-60
ft. lbs. (Fig. 7) Loctite is a registered trademark of Henkel
Corporation.
15. Install internal Cylinder Head O-ring.
16. Place seals on rear gland/sleeve
17. Thread Piston Assembly Tool onto Pull Piston. Using
an arbor press, press Cylinder sleeve over the back
of the piston until seated on piston. Slide complete
Front Gland Assembly and other components, as
shown in Fig.7, over Piston Assembly Tool onto
Piston.
18. Press entire piston, gland assembly, and components
into head. Remove Piston Assembly Tool from piston.
19. 244X: (Fig. 9a) 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.
244OSX: (Fig. 9b) 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 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).
20. Install Quad-Ring (72) and Spacer. Slide
Reservoir Plunger (73) in.
244X: Install two Springs (71)
244OSX: Install Spring (93) rst, then
Spring (71).
21. Screw Housing/Spacer Assembly into
head. (Fig. 1)
22. 244X ONLY: (Fig. 1 & 9a/b)
Push Pintail Deector (22) onto rear of
Piston (18).
22. Place O-ring (39) on Plug (40) and screw assembly into
Handle (1). (Fig. 6)
23. 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 & 9a/b))
24. Tool is now completely assembled except for relief
and check valves. See Fill and Bleed procedure for
replacement of valve components.
Cylinder Head
Cylinder Head
Piston
Assembly Tool
Assembled
Pull Piston and
Front Gland
Piston Assembly
Tool
Assembled
Pull Piston and
Front Gland
Internal Cylinder
Head O-Ring
Assembled
Cylinder Sleeve
Assembled
Cylinder Sleeve
Internal Cylinder
Head O-Ring
FIG. 7
FIG. 6
244 series Pneudraulic Installation Tools (HK989)Alcoa Fastening Systems & Rings
13
Equipment Required:
- Shop airline with 90-100 psi max.
- Air regulator
- Fill Bottle 120337 (supplied with tool).
- Fill Tool Assy 112465 (244X)
- Fill Tool Assy 112465 (244OSX)
- Large at blade screwdriver
- Stall Nut 124090 (244X)
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 uid) (See Fig. 8.)
Rell 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 posi-
tion 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
244X (Fig. 8)
Screw retaining nut onto Head Assembly. Screw Stall Nut
onto Piston and tighten to ensure full thread engagement.
Back o 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.
244OSX (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, and disconnect tool. With ll port facing
up, (check valve on side) lay tool on its side. (Fig. 8)
Step 5
Install ll bottle in head ll port (check valve hole) (Fig. 8).
continued
Model 244
Model 244OS
120337 Fill Bottle
Assembly
FILL POINT
FIG. 8
Model 244X
Model 244OSX
14
244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
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 ll
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).
Step 9
Turn tool so front of head faces you and remove the relief
valve Plug (85). Prior to removing Plug (85), it is advisable
to back out setscrew inside of plug by approximately 1/2
turn counterclockwise. (See Figure 8a). This ensures that
the Piston will remain in full-forward position. Install relief
valve Ball (81), Guide (82), Sleeve (83) and Spring (84).
Replace the Plug (85).
Step 10
244X (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 res-
ervoir housing.
244OSX (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 ll tool.Lay tool on its left side and remove
Plug (40). Top o 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 ll tool and cycle tool as in step 10. Reservoir
may drop slightly. If so, repeat step 11 until when you
touch the ll 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 o.
Step 13
244X (Fig. 8)
Remove ll tool and stall nut. Install a nose assembly and
pull several fasteners to test function.
244OSX (Fig. 8)
Remove ll 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.
FIG. 8a
-
244 series Pneudraulic Installation Tools (HK989)Alcoa Fastening Systems & Rings
15
FIG. 9a
See
Figure 10
16
244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
b
FIG. 9b
See
Figure 10
244 series Pneudraulic Installation Tools (HK989)Alcoa Fastening Systems & Rings
17
(Check Valve Seat)
(Reservoir Fill Plug)
(Relief Valve Plug)
(Check Valve Plug)
(Relief Valve Seat & Seals Assy
)
(Check Valve Seat)
(Reservoir Fill Plug)
(Relief Valve Plug)
(Check Valve Plug)
(Relief Valve Seat & Seals Assy
)
FIG. 10
18
244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
1 1
1
1
1
5 1
1*
1
Stop 1
1
1*
11 1
1
1*
1*
15** 1
1*
1
1
1*
1
1
1
1*
1
1
1
1
1*
1
1
1*
1
1*
1
1
1*
1
1*
1*
1*
1*
1*
1
51** 1
1*
1*
1*
55
1
1
1
1
1
1
1
1
1
Spring 1*
1
1
1
Spring 1+
1*
1
1
1*
1
Spring 1
1
1*
1*
1
1
Spring 1
1
1
1*
1
1
Stop 1
Spring 1
1
1*
1
1
96** 1
1
98** 1
1
1
1
1
1
1
244 series Pneudraulic Installation Tools (HK989)Alcoa Fastening Systems & Rings
19
FIG. 12
ATTACHING NOSE ASSEMBLY
1. Remove Cap Screw (91) and Rotational
Stop (90).
2. Insert a 3/16” hex T-Wrench through Piston
Stop (89) until it engages internal hex in Hydraulic Piston (18).
3. Thread the nose assembly onto the tool until it bottoms out. Then back it off half to one full turn.
4. Install Rotational Stop (90) and secure with Cap Screw (91). The nose should be free to rotate approxi-
mately 45 degrees from the vertical in either direction (90 degrees included).
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 dimen-
sion “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).
20
244 series Pneudraulic Installation Tools (HK989) Alcoa Fastening Systems & Rings
Always check out the simplest possible cause of
a malfunction rst. 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 CHART as an aid in
locating and correcting malfunction.
Note:
Piston Drift is when the air piston is in the down position,
but the hydraulic pull piston is not in the full forward
position. This causes an out of sequence condition.
1 Tool fails to operate when trigger is depressed.
a) Air line not connected
b) Throttle Valve O-rings worn or damaged.
c) Throttle valve Cable Assembly is broken.
2 Tool does not complete fastener installation and
break pintail.
a) Air pressure too low
b) Air Piston Quad-Ring worn or damaged.
c) Reservoir empty or low, refer to Fill and Bleed
section.
d) Air in hydraulic system, refer to Fill and Bleed
section.
e) Reservoir Springs worn or damaged
f) Check for piston drift
3 Pintail stripped and/or swaged collar not ejected.
a) Check for broken or worn jaws in nose assembly
b) Check for loose Retaining Nut
c) Check for piston drift.
4 Tool has piston drift.
a) Loose collet crashing into the front of the anvil,
this causes the relief valve to open allowing the
piston to drift. Tighten the collet and refer to Fill
and Bleed section.
b) Worn or damaged Return Pressure Relief Valve
in tool, inspect Seat Assembly, O-ring,
Back-up Rings, Steel Ball and Valve Spring.
Replace if necessary.
c) Worn or damaged Piston Assembly; Inspect
O-rings and Back-up Rings, and replace if
necessary.
5 Hydraulic uid exhausts with air or leaks at base
of handle.
a) Worn or damaged Gland Assembly; Inspect
Polyseal, O-rings, and Quad-Ring, and replace if
necessary.
6. Hydraulic uid leaks at rear of Pull Piston
a) Worn or damaged Rear Gland; inspect
Polyseal and O-ring, and replace if necessary.
7. Hydraulic uid leaks at front of Pull Piston
a) Worn or damaged Front Gland; Inspect
Polyseal, O-ring , and Back-up Ring, and replace
if necessary.
8. Pull Piston (18) will not return
a) Throttle Valve stuck; Lubricate O-rings.
b) Throttle Arm, Cable Assembly or Trigger binding.
9. Air leaks at air Cylinder Head
a). Worn or damaged O-ring. Replace if
necessary.
244X TOOL
Fill and Bleed Bottle (Fig.8) - 120337
Seat Removal Tool - 126136
Fill Tool Assy for reservoir (Fig.8) - 112465
Stall Nut (Fig.8) - 124090
Retaining Nut (for“Jiffy”stylenoses) - 125412
Piston Assy Tool Kit Includes: - 123110-11
Piston Assembly Tool (Fig. 2) - 123111-2
Spacer (Fig. 2) - 123112-2
Service Tool Kit Includes: - 120352-244
Fill and Bleed Bottle (Fig.8) - 120337
Fill Tool for reservoir (Fig.8) - 112465
Stall Nut (Fig.8) - 124090
Pintail Collection Bag - 125655
Pintail Tube (for -05 fastener) - 100534-1
Air Cylinder Boot - 129458
244OSX TOOL
Fill and Bleed Bottle (Fig.8) - 120337
Seat Removal Tool - 126136
Fill Tool Assy for reservoir (Fig.8) - 112465-1
Main Piston Assembly Tool Kit - 123110-10
Includes:
Piston Assembly Tool (Fig. 2) - 123111-8
Spacer (Fig. 2) - 123112-8
Service Tool Kit Includes: - 120352-244OS
Fill and Bleed Bottle (Fig.8) - 120337
Fill Tool Assy (Fig.8) - 112465
Air Cylinder Boot - 129458
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1
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