Huck 201 User manual

07-15-2005
HK958
INSTRUCTION MANUAL
2015 ALL MODELS
PNEUDRAULIC INSTALLATION TOOL

2015 Series Tooling Alcoa Fastening Systems
2
Huck Model 201 (family) Sound Level
SEL --- 75.7 dB (A)
peak value = 104.4 dB (C)
For an eight hour work day, installing 3000 typical Huck
fasteners will result in an equivalent noise level (Leq) of
65.9 dB (A).
To calculate equivalent noise level for other quantities of
fasteners in an eight hour period, use the formula:
Leq = SEL + 10 log (n/28,800)
where n = number of fasteners in eight hours.
Huck Model 201 (family) Vibration Level
For an eight hour work day, installing 3000 typical Huck fas-
teners will result in an equivalent weighted RMS
vibration level (Aeq) of 12.25rn/s2.
To calculate the equivalent vibration level for other
quantities of fasteners in an eight hour period, use the for-
mula:
Equivalent Vibration Level, Aeq (rn/s2) = (n/480) x 1.96
where n = number of fasteners in eight hours, and 1.96
(m/s2) = Aeq for 60 seconds
EU Declaration of Conformity
Manufacturer:
Huck International Inc., Installation Systems Division, 85 Grand Street, Kingston, NY, 12401,
USA
Description of Machinery:
Model number 201 family of fastener installation tools
Relevant provisions complied with:
Council Directive related to Machinery, (89/392/EEC), (91/368/EEC), (93/44/EEC),
(93/68/EEC)
European Representative:
Rob Pattendon, 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: Renno Budziak
Position: Vice President of Engineering, Installation Systems
Division
Place: Kingston, New York, USA
Date: November, 1995
Test data to support the above information is on file at Huck International, Inc. Kingston, N.Y. Vibration
measurements are frequency weighted in accordance with ISO 8041 (1990).

2015 Series Tooling Alcoa Fastening Systems
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EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SERVICING THE TOOL
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Filling and Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . .14-15
How to Measure Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-22
SUB-ASSEMBLY PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
CONTENTS

2015 Series Tooling Alcoa Fastening Systems
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SAFETY
This instruction manual must be read with particular
attention to the following safety guide lines, by
any person servicing or operating this tool.
1. Safety Glossary
WARNINGS - Must be understood
to avoid severe personal injury.
CAUTIONS - show conditions that will dam-
age equipment and or structure.
Notes - are reminders of required proce-
dures.
Bold, Italic type and underlining - empha-
sizes a specific instruction.
2. Huck 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.
3. Repairman and Operator must read manual prior
to using equipment and understand any Warning
and Caution stickers/labels supplied with equip-
ment before connecting equipment to any pri-
mary power supply. As applicable, each of the
sections in this manual have specific safety and
other information.
4. See MSDS Specifications before servicing the
tool. MSDS Specifications are available from
you Huck representative or on-line at
www.huck.com. Click on Installation Systems
Division.
5. When repairing or operating Huck installation
equipment, always wear approved eye protec-
tion. Where applicable, refer to ANSI Z87.1 -
1989
6. Disconnect primary power source before doing
maintenance on Huck equipment.
7. If any equipment shows signs of damage, wear,
or leakage, do not connect it to the primary
power supply.
8. Make sure proper power source is used at all
times.
9. Never remove any safety guards or pintail
deflector.
10. Never install a fastener in free air. Personal
injury from fastener ejecting may occur.
11. When using an offset nose always clear spent
pintail out of nose assembly before installing the
next fastener.
12. If there is a pinch point between trigger and
work piece use remote trigger. (Remote trig-
gers are available for all tooling).
13. Do not abuse tool by dropping or using it as a
hammer. Never use hydraulic or air lines as a
handle. Reasonable care of installation tools by
operators is an important factor in maintaining
tool efficiency, eliminating downtime, and in pre-
venting an accident which may cause severe
personal injury.
14. Never place hands between nose assembly and
work piece.
15. Tools with ejector rods should never be cycled
with out nose assembly installed.
16. When two piece lock bolts are being used
always make sure the collar orientation is cor-
rect. See fastener data sheet of correct posi-
tioning.
!
Product complies with requirements
set forth by the relevant European
directives.
Read manual prior to using
equipment.
Eye protection required while
using this equipment.
Hearing protection required while
using this equipment.

2015 Series Tooling Alcoa Fastening Systems
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•Min. Stroke: .683
•Air Pressure: 90-100 psi
•Speed/Cycles: 30 per minute
•Air Consumption: 4.3 CFM
The Model 2015 series tools are lightweight,
high speed production tools designed to install
3/32 and 1/4 nail type blind fasteners. An inte-
gral nose assembly increases reliability and
simplifies use of this tool.
The 2015V, with vacuum boost selector switch
ON, has two functions:
1. With tool in any position, vacuum holds
fastener firmly in nose assembly.
2. Vacuum expels broken pintail into pintail
collector.
Pulling action of the pull piston is provided by
a pneumatic-hydraulic (pneudraulic) intensifier
system powered by 90-100 psi air pressure.
The air inlet is equipped with a connector with
1/4-18 female pipe threads to accept your air
hose or quick connect fitting. The piston return
stroke is spring actuated.
•Weight of 2015: 4.9 lbs
•Weight of 2015B & 2015V: 5.2 lbs
•Min. Capacity: 2670 lbs @ 90 psi
Fasteners installed: Consult your Huck representative or available FASTENER SELECTION
CHARTS.
Hydraulic Fluid: Automatic Transmission Fluid, DEXRON Ill, or equivalent.
DESCRIPTION
SPECIFICATIONS

2015 Series Tooling Alcoa Fastening Systems
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Fig. 1
2015 and 2015B
Outline Dimensions

2015 Series Tooling Alcoa Fastening Systems
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2015V Outline Dimensions
Fig. 1A

When tool is connected to proper air supply,
air pressure holds throttle valve in the up position.
Air pressure is directed to the top of piston keep-
ing it down. Depressing trigger moves throttle
valve to the down position. Air is directed to the
bottom of the piston moving it upward, air from
above piston is exhausted downward thru the
throttle valve and exits the muffler at bottom of
tool. Air piston rod is a hydraulic piston.
Pressurized fluid is forced into the cylinder head
moving pull piston rearward. The nose, which is
connected to the pull piston, will install the fas-
tener during the rearward piston movement.
When fastener installation is completed, and
upon trigger release, air pressure causes throttle
valve to return to its up position. Air flow reverses.
The air piston and rod move down to their starting
position, exhausting air from below the piston
through the muffler at bottom of tool. As rod
moves downward and hydraulic pressure is
released from pull piston, a spring behind pull
piston returns it to its starting position.
2015 Series Tooling Alcoa Fastening Systems
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PRINCIPLE OF OPERATION
Fig. 2
Main Components

The 2015 is shipped with a plastic plug in the air
inlet connector. Connector has 1/4-18 female pipe
threads to accept the hose fitting. Quick connect fit-
tings and 1/4 inch inside diameter air hose are rec-
ommended. An air supply of 90-100 psi, capable of
2.9 CFM, must be available. Air supply should be
equipped with a filter-regulator-lubricator unit.
1. Remove plastic plug from air inlet connector and
drop in a few drops of Automatic Transmission
Fluid, DEXRON Ill, or equivalent.
2. Screw quick-connect fitting into air inlet connec-
tor.
3. Set air pressure on regulator to 90-100 psi.
4. Attach optional air hose, 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.
9. Select correct nose assembly from the available
SELECTION CHARTS or speak with your Huck
representative.
NOTE: Quick disconnect fittings and air hoses are
not available from Huck.
2015 Series Tooling Alcoa Fastening Systems
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PREPARATION FOR USE
!
WARNING
As applicable, do not use without deflectors or
pintail bottles. If deflectors are removed or dam-
aged, separated pintails may eject forcibly from
rear of tool. Unshielded eyes, especially, may be
permanently injured. Other severe injuries can
be caused by flying pintails. If there is any
chance of a projectile-like ejection, always point
rear of tool in a safe direction, or be sure there
is some structure that will stop ejecting pintails.
WARNING
To avoid pinch points, be sure there is
adequate clearance for tool and operator’s
hands before proceeding. Tool moving toward
structure may crush hands or fingers between
tool and structure if clearance is limited.
!
OPERATING INSTRUCTIONS
NOTE: 2O15V is sold with the ribbed vacuum control
ON/OFF slide in the forward or OFF position. See FIG-
URE 6 for slides location which is shown in the ON (rear)
position. While tool is not being used, move slide to the
OFF (forward) position to prevent unnecessary air loss.
Blind Fastener Installation:
The fastener may be placed either in the work hole or in
the end of the nose assembly. In either case, tool and
nose assembly must be held against work and at right
angles to it. Depress trigger and hold it depressed until
fastener is installed and pintail breaks. Release trigger.
!
WARNINGS
Inspect tool for damage before each use. Do not
operate if damaged as severe personal injury may
occur.
Broken pintails eject from deflector with speed
and force - - be sure pintail deflector is directed
safely away front operator or the personnel in the
area. Ejecting pintails striking anyone may cause
serious personal injury. For Models 2015B and
2015V, pintail bottles must always be used.
Replace damaged pintail deflectors and bottles as
serious personal injury may occur from pintails
when using these defective parts.

2015 Series Tooling Alcoa Fastening Systems
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Good Service Practices
Service Kits, 2015KIT and 2015VKIT. include perishable
parts and should be on hand at all times. Other compo-
nents, as experience dictates, should also be kept for
replacements. ALWAYS REPLACE O-RINGS AND
BACK-UP RINGS WHEN TOOL IS DISASSEMBLED
FOR ANY REASON.
The efficiency and life of any tool depends upon proper
maintenance and good service practices. Tool should be
serviced by personnel who are thoroughly familiar with it
and how it operates.
A clean, well-lighted area should be available for servic-
ing the tool. Special care must be taken to prevent con-
tamination of pneumatic and hydraulic systems. Proper
hand tools and soft materials to protect tools must be
available, Use only standard hand tools, brass drift and
wood block. Vise with soft jaws should be available.
Unsuitable hand tools will cause installation tool damage.
All parts must be handled carefully and examined for
damage and/or wear. Components should be disassem-
bled and assembled in a straight line without bending,
cocking or undue force. Disassembly and assembly pro-
cedures outlined in this manual should be followed. If
Huck recommended procedures are not followed, the tool
may be damaged.
Rub SLIC-TITE TEFLON* thread compound, or equiva-
lent, on pipe plug threads and quic connect fitting.
CAUTION: Do not use TEFLON tape on pipe threads.
Pipe threads may cause tape to shred resulting in
tool malfunction. (SLIC-TITE is available in stick
form, as 503237, from Huck.)
Smear LUBRIPLATE 13OAA*, or equivalent lubricant, on
O-rings and mating surfaces to aid assembly and to pre-
vent damage to O-rings. (LUBRIPLATE 13OAA is avail-
able in a tube, as 502723, from Huck.)
Use VIBRA-TITE* or equivalent on Gland Housing Assy,
116134-1, threads. Torque to 75-80 ft. lbs.
Apply LOCKTITE* #271 Adhesive/sealant to Locknut,
505420. (LOCKTITE is available from Huck, in a tube, as
503657.) Torque to 25-30 ft. lbs.
* TEFLON is a trademark of E.l. DuPont de
Nemours & Co.
* LOCTITE is a trademark of Loctite Corp.
* TRUARC is a trademark of Waldes Kohinoor, Inc.
* VIBRA-TITE is a trademark of the Oakland
Corporation.
* LUBRIPLATE is a trademark of Fiske Brothers
Refining Co.
Standard Tools Available from Huck
1/8 hex key 502294 used on button head screw 504127.
5/32 hex key 502295 used on socket cap screw 123756.
(0400) TRUARC pliers 502866 used on (N5100-l00)
retaining ring.
MAINTENANCE
Tool Maintenance
The 2013 series require a minimum amount of mainte-
nance. Regular inspection and correction of minor prob-
lems will keep the tool operating efficiently and prevent
downtime.
Using filter-regulator-lubricator unit is highly recommend-
ed for safe and reliable tool operation. If a filter-regulator-
lubricator unit is not being used in the air supply: (1)
remove hose fitting from air inlet connector and drop in a
few drops of automatic transmission fluid or light oil (2)
blow out air line to remove dirt and water before connect-
ing air hose to tool. At regular intervals, depending upon
use, replace all seals in tool. Service Kits should be kept
on hand. (See SPARE PARTS AND SERVICE KITS.)
Inspect both hydraulic pistons, and their piston rods for
scored surfaces, excessive wear or damage, and replace
as necessary.
Always replace seals and back-up rings when tool is
disassembled for any reason to assure proper sealing
and tool function.
Nose Assembly Maintenance
CAUTION: Damaged jaw teeth, or debris packed
between teeth, will result in failure to install fastener
or improperly installed fastener.
Frequently cleaning the nose assembly is recommended.
Remove nose assembly from tool and disassemble. See
DISASSEMBLY Check components for any signs of dam-
age, e.g. cracks, scores and spring damage. Check grip-
per teeth for damage. Remove any debris packed
between teeth with a sharp pointed ‘pick’. Periodically dip
nose, while cycling tool, in mineral spirits, isopropyl alco-
hol or other suitable solvent, to clean jaws and wash
away metal chips and dirt.
PREVENTIVE MAINTENANCE

2015 Series Tooling Alcoa Fastening Systems
11
DISASSEMBLY
The following procedure is for complete disassembly.
Disassemble only subassemblies necessary to check
and replace damaged or worn seals, wipers, back-up
rings and other components. Always replace seals,
wipers, and back-up rings of disassembled sub-
assemblies.
1. Disconnect tool from air source.
2. Unscrew Retaining Nut and remove nose assembly.
3. Unscrew Bleed Plug (Figure 7), including O-ring,
from top of Handle/head. Turn tool over and allow
fluid to drain into container. Tool may be cycled to
clear tool more completely. Discard fluid.
4. Pull Pintail Deflector off End Cap.
5. Remove Throttle Arm Pivot Screw and lift out throt-
tle arm. Disconnect ball end of Cable Assembly
from throttle arm. (Figures 8 & 9)
6. Hold tool in vise with bottom up. Remove Button
Head Screws (3) with 1/8 hex key. Remove End
Cap and Gasket. Remove Muffler from end cap.
Remove Spring from Throttle Valve.
7. To loosen Cylinder Head Retaining Ring in Cylinder,
tap Cylinder Head with mallet. Remove Retaining
Ring.
8. NOTE: Screw Button Head Screws back into
Cylinder Head. Carefully pull or pry on screws to
remove head.
9. To remove air piston from cylinder, pull on Locknut
with vise-grip pliers.Note: Air piston and rod should
not be disassembled. If lock nut loosens, apply
LOCTITE #271 and tighten to 25-30 ft. lbs. CAU-
TION: Do not scratch, nick or ding Piston Rod.
This will cause permanent hydraulic leakage.
10. Remove Bumper from Gland Assembly. Unscrew
gland with 1 3/8 socket wrench and extension bar.
11. Remove Retaining Ring from gland. Pull out Spacer
and Polyseal.
12. Lift cylinder from handle/head.
13. Turn handle/head over and drain fluid into contain-
er. Discard fluid.
14. Pull Throttle Valve out of cylinder. Note: Service on
Throttle Valve Bushings is not normally required.
CAUTION: Only if air leakage is not correctable-
with new Throttle Valve Seals, Bushings should
be replaced in Cylinder.
15. Press out Lower Bushing and Upper Bushing. Use
square ended brass rods at least six inches long.
With proper diameter rod, press out lower bushing
first, and then press out upper bushing using a larg-
er size rod.
16. Place handle/head securely in vise. Remove End
Cap with 15/16” open end wrench. Extract Spring,
Washer and Wiper Seal. CAUTION: If Piston
Seals and Gland Seals must be reused, help
prevent damaging them by installing optional
Polyseal Insertion/removal Tool (121694-202) in
rear of Handle/head.
REMOVAL OF PISTON AND FRONT GLAND (Figure 10)
17. Thread Polyseal Insertion/removal Tool, 121694-
202, into Handle/head.
18. Slide Spacer, 123112-3, onto piston. Thread Piston
Assembly (bullet) Tool, 123111-4 onto piston.
19. Push complete piston from front using brass drift.
Allow clearance, with stand-off, for piston as it
leaves tool.
20. Remove Piston Assembly Bullet, Spacer and
Polyseal Insertion/removal Tool. NOTE: Inspect
hydraulic piston for wear, scoring or damage.
Replace when necessary.
21. Unscrew Adapter, 125132, with wrench.
22. Inspect all seals and parts.
23. Remove trigger cable assembly by removing pin
with parallel punch. Remove dowel pin to discon-
nect cable from trigger.
continued
!
WARNING:
Air hose must be disconnected before:
• Removing or attaching nose assembly.
• Cleaning tool and/or nose assembly.
• Replacing worn or damaged tool
components.
Tool may be activated if not disconnected and
cylinder is under pressure. Fingers may be
severely pinched/lacerated. Other severe per-
sonal injury may result.

2015 Series Tooling Alcoa Fastening Systems
12
67
8
5
3
4
2
1
Special Disassembly Instructions for 2015B and 2015V
1. Remove Vacuum Tube from Cylinder.
(2015V only)
2. Place handle/head securely in vise.Use
0100 TRUARC pliers, 502857, to remove
retaining ring. Reach through window of
pintail bottle. Remove washer.
3. Remove pintail bottle.
4. Remove bottle adapter and vacuum
ON/OFF slide.
5. Remove end cap assembly
and spring.
6. Remove washer and O-ring
from spring side of end cap.
7. Remove retaining ring on bottle side of end
cap. Remove spacer, wiper seal, washer
and O-ring.
8. Remove O-rings from ON/OFF slide.
DISASSEMBLY (continued)
Figure 3

2015 Series Tooling Alcoa Fastening Systems
13
See MAINTENANCE: GOOD SERVICE PRACTICE.
Clean all components with mineral spirits, and inspect
for wear or damage. Replace as necessary.
CAUTION: Always replace all seals, wipers and
back-up rings on/in disassembled components.
These parts wear from friction and deteriorate with
age. Replacement prevents potential leakage.
Use seals, wipers and back-up rings supplied in SER-
VICE KIT, 2015KIT and 2015VKIT -see NOTES. Smear
LUBRIPLATE 130AA or PARKER-O-LUBE on seals.
Figures 3 through 12.
1. If Bushings have been removed from cylinder:
Use an arbor press and apply LOCTITE #609,
(503377) on bushings before being pressed into
cylinder. Place chamfered end of Upper Bushing In
top of Cylinder. Carefully press bushing squarely
into cylinder. Repeat procedure for Lower Bushing.
2. Assemble Gland Assembly after replacing Polyseal,
Spacer and Retaining Ring. Figure 8. NOTE: Cup of
POLYSEAL must face toward top of tool when
installed in Gland.
3. Install Adapter into cylinder handle/head.
4. Thread Polyseal insertion/removal tool, 121694-202
into handle/head.
5. Thread Piston Assembly Tool 123111-4, onto Piston
Assembly.
6. Push front gland assembly onto piston, as shown.
7. Slide wiper onto piston, as shown.
8. Push assembled components in gently from rear of
tool using a press or soft mallet and wood or brass
drift.
9. Remove Piston Assembly Tool and Polyseal
Insertion/removal Tool.
10. For 2015: Assemble Spring, Spacer, Rear Wiper
Seal and End Cap into handle/head.
For 2015B or 2015V:Reverse the disassembly
instructions in the Special Disassembly
Instructions for 2015B and 2015V in the
Disassembly section.
11. Figure 5 - Position Cable Assembly in Trigger slot
and push Dowel Pin through holes in trigger and
cable assembly. Position assembled trigger in han-
dle and drive Pin through holes in handle and trig-
ger.
12. Hold handle/head in vise with lower end pointing up.
Turn cylinder bottom up, and position on handle by
lining up cylinder pin with handle hole.
13. Apply VIBRATITE or equivalent to threads of Gland
Assembly. Screw gland into head/handle. Using a
1 3/8 socket wrench, tighten gland to 75-80 ft. lbs.
14. Push Bumper firmly over gland, slots must face
toward bottom of tool.
15. Lubricate piston rod. Press assembled air piston/pis-
ton rod into cylinder just enough to allow installation
of cylinder head.
16. Push Cylinder Head squarely into cylinder taking
care not to damage O-ring. Install Retaining Ring.
Align screw holes with muffler end cap.
17. Position Muffler in center of cylinder head. Position
Gasket on cylinder.
18. Carefully position Muffler End Cap on cylinder. Be
certain that muffler is properly positioned in
recess of muffler end cap.
19. Muffler end cap is secured with three Button Head
Screws. Tighten with 1/8 hex key.
20. Place tool upright on level surface. Drop Spring into
throttle valve bore in cylinder. Push Throttle Valve
into cylinder.
21. Place ball end of Throttle Cable in end of Throttle
Arm.
22. Slide Throttle Arm into slot on Cylinder.
23. Install Pivot Screw in cylinder to retain Throttle Arm.
24. Follow FILLING AND BLEEDING PROCEDURE of this man-
ual to fill tool.
25. Install Bleed Screw afte filling and bleeding proce-
dure.
26. Screw Anvil Insert into Anvil Holder.
27. Assemble components into Collet, as shown in
Figure 5. Screw assembled collet onto piston rod.
Tighten securely.
28. Screw assembled anvil holder and insert into
Adapter.
ASSEMBLY

Equipment Required:
• Shop airline with 90 - 100 psi max.
• Air regulator
• Fill bottle, 120337, (supplied with tool).
• Large flat blade screwdriver
• Nose assembly or optional stall nut
• Fasteners (optional)
• Optional stall nut and stop
Stall nut, 125340 and stop, 125341
Stall nut is used to load tool during bleeding
and for measuring stroke.
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). Figure 4.
Procedure to Fill Empty Tool (new or
rebuilt):
1. Attach the tool air source momentarily to seat air
piston at bottom of cylinder and disconnect tool.
With fillport facing up, lay tool on its side.
2. With a screwdriver, remove bleed plug fromfillport.
3. Screw fill bottle into fillport in the head.
4. Set airline pressure to 20-40 psi and connect airline
to tool.
5. Stand tool upright on bench. While triggering tool
slowly (20-30 cycles), bend fill bottle at right angles
to tool. Figure 4.2. Air bubbles will emerge from
tool. When bubbles stop, cycling may be discontin-
ued.
6. When trigger is released, pull piston returns to idle
position (full forward). Disconnect tool from airline.
7. Lay tool on its side. Remove fill bottle. Top off fluid
in fillport. Install bleed plug and tighten.
8. Connect airline to tool. There is a choice of two pro-
cedures for measuring the stroke: with and without
a stall-nut. See appropriate section and follow the
selected procedure. If stroke is less than specified,
remove bleed plug and top off fluid. Reinstall bleed
plug.
continued
2015 Series Tooling Alcoa Fastening Systems
14
FILLING AND BLEEDING PROCEDURE
Fill Point
120337 Fill Bottle
Assembly Includes:
120336 Container
120004 Connector
CONTAINER
( ISCAR FLUI )
Fig. 4
Fig. 4.1
WARNING: Air pressure MUST be set to 20-40
psi to prevent possible injurious high pressure
spray. Never cycle tool without bleed plug
tightened, fill bottle tightened in tool, or fillport
held over a receptacle Figure 4.1 When not
properly contained any fluid present in tool
will spray out. Severe injury may result.
!
Fig. 4.2

9. Increase air pressure to specification. Install two
fasteners to check function and installation in a sin-
gle 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 again. Measure again. Continue this process
until stroke meets minmum requirements.
Bleed Procedure for Partially Filled Tool in
Field Use:
1. Disconnect tool from airline. With fillport facing up,
lay tool on its side.
2. Remove bleed plug from bleed port.
3. Hold tool over suitable container with fillport facing
into container.
4. Connect tool to airline. Cycle tool several times to
drain the old fluid, air and foam.
5. Screw fill bottle into fillport.
6. See WARNING above. With air pressure set at 20-
40 psi, connect airline to tool.
7. Stand tool upright on bench. While actuating the
trigger slowly (20-30 cycles), bend fill bottle at right
angles to tool. Figure 4.2. Observe that air bubbles
emerge from tool. When bubbles are no longer
observed, cycling may be discontinued.
8. When trigger is released, pull piston returns to idle
position (full forward). Disconnect tool from airline
with piston full forward.
9. Lay tool on its side. Remove fill bottle. Top off fluid
in fillport. Install bleed plug and tighten with screw-
driver.
10. Connect airline to tool. There is a choice of two pro-
cedures for measuring the stroke: With and without
a stall-nut. See appropriate section and follow the
selected procedure. If stroke is less than specified,
remove bleed plug and top off fluid. Reinstall bleed
plug.
11. Install two fasteners to check function and installa-
tion in a single stroke, or cycle tool with stallnut fully
threaded onto piston. Measure stroke again.
Remove plug and top off fluid. Reinstall plug and
cycle again. Measure again. Continue this process
until stroke meets minimum requirements.
2015 Series Tooling Alcoa Fastening Systems
15
FILLING AND BLEEDING PROCEDURE (continued)
WARNING: Air pressure MUST be set to 20-40
psi to prevent possible injurious high pressure
spray. Never cycle tool without bleed plug
tightened, fill bottle tightened in tool, or fillport
held over a receptacle Figure 4.1 When not
properly contained any fluid present in tool
will spray out. Severe injury may result.
!
CONTAINER
( ISCAR FLUI )
Fig. 4.1
Fig. 4.2

2015 Series Tooling Alcoa Fastening Systems
16
To measure stroke of tool without
stall-nut:
1. Disconnect tool from airline and remove nose
from tool.
2. Reconnect tool to airline, with piston fully forward
(end of RETURN stroke), measure and record “X”
dimension. Figure 4.4.
3. Hold trigger depressed. Piston is now fully to the
rear and at end of PULL stroke. Measure and
record “Y” dimension.
4. Subtract “X” dimension from “Y” dimension.
5. If stroke is less than .650, refer to appropriate
previous section. Follow filling and topping off
instructions.
Fig. 4.4
Fig. 4.3
1. Disconnect tool from airline and remove
nose from tool.
2. Reconnect tool to airline. Cycle tool and
hold trigger depressed. This keeps piston
fully to the rear and at end of PULL
stroke. Thread stall-nut back onto piston
until it contacts stop.
3. Release trigger. Stall-nut will move forward
with piston. Figure 4.3 and measure ‘X”
dimension. This is the tool’s stroke.
4. If stroke is less than .650, refer to appro-
priate previous section. Follow’ filling and
topping off instructions.
To measure stroke of tool with stall-nut
threaded onto piston:
HOW TO MEASURE STROKE

2015 Series Tooling Alcoa Fastening Systems
17
123770 End Cap &
Adapter Assembly
123772
Pintail Bottle
125150
End Cap
506488
Wiper*
124828
Washer
125132
Adapter
505539 Spring
116912 Cap
125796-1 Piston
(see Note above)
500621 Pin
124333-1
Trigger
505496
owel Pin
116404-1
Cable
Assembly
123766
Handle
Assembly
125154 Insert -06 or
125155 Insert -08
125138 Collet
126133 Chuck Jaws
125134 Follower
125133 Anvil Holder
2015 Head / Handle
506492
Spring
1
124211
Pintail
eflector
506628
Washer
501007
Retaining
Ring
506628
Washer
501007
Retaining
506488
Wiper*
124828
Washer
2015B Head / Handle
All components same as
2015 excepted as listed.
*Note orientation of
Wipers and Polyseals.
505817
Wiper*
122432
Gland Cap
505818
Polyseal*
501110
Back-up
Ring 500816
O-ring
123757
Front
Gland
506160
Polyseal*
506654
Washer
506653
Retaining Ring
Note:
Piston 125796 is not sold separately.
It may be purchased as: Piston
Assembly 125156, hich includes the
Piston along ith Polyseal 506160,
Retaining Ring 506653, and Washer 506654.
1For other available assemblies,
see Subassembly Part Numbers
and Notes section of this manual.
Figure 5

2015 Series Tooling Alcoa Fastening Systems
18
506648 Washer
124245 Slide & Tube Assembly
(shown in ON position)
123577 End Cap
500790 O-ring
500778 O-ring
500790 O-ring 500807
O-ring
506628 Washer
501007 Retaining Ring
502310 Retaining Ring
123578 Spacer
506488 Wiper*
124828 Washer
123784 Adapter
125132 Adapter
505539 Spring
116912
Cap
500621 Pin
124333-1 Trigger
505496 owel Pin
116404-1 Cable Assembly 123766
Handle Assembly
125154 Insert -06 or 125155 Insert -08
125138 Collet
126133
Chuck
Jaws 125134
Follower
125133 Anvil Holder
123772
Pintail Bottle
2015V Head / Handle
506492 Spring
505817
Wiper*
122432
Gland
Cap
505818 Polyseal*
501110
Back-up
Ring 500816
O-ring
123757 Front Gland
506160 Polyseal*
506654 Washer
506653 Retaining Ring
*Note orientation
of Wipers and
Polyseals.
125796-1 Piston
(see Note above)
1
Note:
Piston 125796-1 is not sold separately.
It may be purchased as: Piston
Assembly 125156-1, hich includes the
Piston along ith Polyseal 506160,
Retaining Ring 506653, and Washer 506654.
1For other available assemblies,
see Subassembly Part Numbers
and Notes section of this manual.
Figure 6

2015 Series Tooling Alcoa Fastening Systems
19
3
3For available assemblies,
see Subassembly Part Numbers
and Notes belo .
125116
Guard 505438 O-ring
100309 Bleed Plug
506576 Plug &
Gasket Assembly
Figure 7
Swivel Bolt Subassembly
Fill Plug and O-ring Subassembly
1 123775 Front Gland Assembly contains:
123757 Front Gland
500816 O-ring
501110 Back-up Ring
505818 Polyseal
122432 Gland Cap
505817 Wiper
2 123777-2 Air Piston and Rod Assy contains:
123776-1 Air Piston Assembly
111803-1 Piston Rod
506493 Washer
505420 Self-locking Nut
3 104293 Bleed Plug Assembly contains:
100309 Bleed Plug
505438 O-ring
4 123778-1 Cylinder Head Assy contains:
111959-2 Cylinder Head
500864 O-ring
5 125472-2 Throttle Valve Assembly contains:
125467-2 Throttle Valve
507396 O-rings (qty. 3)
NOTE: Install cups of POLYSEALS positioned as
shown. Position wipers as shown.
SUBASSEMBLY PART NUMBERS AND NOTES
Some parts are available separately as well as in subassemblies. Refer to figures 5, 6, 7, 8,
and 9 on the previous and following pages for these parts listed below.

2015 Series Tooling Alcoa Fastening Systems
20
Pivot
Screw
123754-1
Throttle Arm
125467-2
Throttle Valve
507396
O-ring (3)
116272
Spring
Throttle
Cable
AA
5
4
For available assemblies, see
Subassembly Part Numbers and
Notes section of this manual.
2
2
123753-1 Air Piston
111959-2 Cylinder Head
506493
Washer
505420
Locknut
115554-2
Muffler
116585-2
End Cap 504127 Screw (3)
506878 Retaining Ring
500864 O-Ring
501451 QUA Ring
126941 Gasket
125118
Pivot
Screw
Section A A
500778
O-ring
500779
O-ring
(2)
507164
Swivel
Assembly
111803-1
Piston Rod
125139 Gland
Housing
500786 O-ring
506566 Polyseal
123906 Spacer
506565
Retaining Ring
500784
O-ring
501090
Back-up
Ring
501414
QUA -Ring
Figure 8
2015 Air Cylinder
116134-1 Gland Assembly
Figure 9
Throttle Valve Subassembly
and Related Components