Alcoa 243 Instruction Manual

Download

Page 1

04-01-2013

HK1051

INSTRUCTION MANUAL

243

PNEUDRAULIC INSTALLATION TOOL

Page 2

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

Page 3

THREADLOCKER RECOMMENDATION

Loctite® 243 THREADLOCKER

TO REPLACE Vibra-Tite® IN

HUCK

PNEUDRAULIC INSTALLATION TOOLS

In order to ensure ease of assembly of back caps and air pistons, among other components of HUCK installation equipment, it is recommended that wherever Vibra-Tite® has been mentioned in a HUCK instruction manual or product bulletin procedure, the product Loctite® 243 Threadlocker be used instead.

This oil-tolerant, removable, medium-strength blue threadlocker is designed for locking and sealing threaded components. It can be applied smoothly and will now be the HUCK recommended standard for these applications. For best results, follow manufacturer’s recommendations for use.

Loctite® 243 Threadlocker is available for purchase from HUCK in a .5 mL tube as part number 508567.

Locite is a registered trademark of Henkel Corporation, U.S.A.

Vibra-Tite is a registered trademark of ND Industries, Inc. USA.

For more informaƟ on or to order, please contact your local distributor or call direct: Alcoa Fastening Systems

1 Corporate Drive Kingston, NY 12401 800-278-4825

PKG: 8452 GRP: 01 through 12, 15 through 19, & 21-22

Page 1 of 1

January 29, 2014

PB618

Page 4

This page is intentionally blank.

Page 5

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

EU DECLARATION OF CONFORMITY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SAFETY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

PRINCIPLE OF OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

PREPARATION FOR USE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

MAINTENANCE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

OPERATING INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

FILL AND BLEED

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13

ASSEMBLY DRAWING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

PARTS LIST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

ACCESSORIES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

ONTENTS

Page 6

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

I. GENERAL SAFETY RULES:

1. A half hour long hands-on training session with qualified personnel is recommended before using Huck equipment.

2. Huck equipment must be maintained in a safe working condition at all times. Tools and hoses should be inspected at the beginning of each shift/day for damage or wear. Any repair should be done by a qualified repairman trained on Huck procedures.

3. For multiple hazards, read and understand the safety instructions before installing, operating, repairing, maintaining, changing accessories on, or working near the assembly power tool. Failure to do so can result in serious bodily injury.

4. Only qualified and trained operators should install, adjust or use the assembly power tool.

5. Do not modify this assembly power tool. This can reduce effectiveness of safety measures and increase operator risk.

6. Do not discard safety instructions; give them to the operator.

7. Do not use assembly power tool if it has been damaged.

8. Tools shall be inspected periodically to verify all ratings and markings required, and listed in the manual, are legibly marked on the tool. The employer/operator shall contact the manufacturer to obtain replacement marking labels when necessary. Refer to assembly drawing and parts list for replacement.

9. Tool is only to be used as stated in this manual. Any other use is prohibited.

10. Read MSDS Specifications before servicing the tool. MSDS specifications are available from the product manufacturer or your Huck representative.

11.Only genuine Huck parts shall be used for replacements or spares. Use of any other parts can result in tooling damage or personal injury.

12.Never remove any safety guards or pintail deflectors.

13.Never install a fastener in free air. Personal injury from fastener ejecting may occur.

14.Where applicable, always clear spent pintail out of nose assembly before installing the next fastener.

15.Check clearance between trigger and work piece to ensure there is no pinch point when tool is activated. Remote triggers are available for hydraulic tooling if pinch point is unavoidable.

16.Do not abuse tool by dropping or using it as a hammer. Never use hydraulic or air lines as a handle or to bend or pry the tool. Reasonable care of installation tools by operators is an important factor in maintaining tool efficiency, eliminating downtime, and preventing an accident which may cause severe personal injury.

17.Never place hands between nose assembly and work piece. Keep hands clear from front of tool.

18.Tools with ejector rods should never be cycled with out nose assembly installed.

19.When two piece lock bolts are being used always make sure the collar orientation is correct. See fastener data sheet for correct positioning.

II. PROJECTILE HAZARDS:

1. Risk of whipping compressed air hose if tool is pneudraulic or pneumatic.

2. Disconnect the assembly power tool from energy source when changing inserted tools or accessories.

3. Be aware that failure of the workpiece, accessories, or the inserted tool itself can generate high velocity projectiles.

4. Always wear impact resistant eye protection during tool operation. The grade of protection required should be assessed for each use.

5. The risk of others should also be assessed at this time.

6. Ensure that the workpiece is securely fixed.

7. Check that the means of protection from ejection of fastener or pintail is in place and operative.

8. There is possibility of forcible ejection of pintails or spent mandrels from front of tool.

III. OPERATING HAZARDS:

1. Use of tool can expose the operator’s hands to hazards including: crushing, impacts, cuts, abrasions and heat. Wear suitable gloves to protect hands.

2. Operators and maintenance personnel shall be physically able to handle the bulk, weight and power of the tool.

3. Hold the tool correctly and be ready to counteract normal or sudden movements with both hands available.

4. Maintain a balanced body position and secure footing.

5. Release trigger or stop start device in case of interruption of energy supply.

6. Use only fluids and lubricants recommended by the manufacturer.

7. Avoid unsuitable postures, as it is likely for these not to allow counteracting of normal or unexpected tool movement.

8. If the assembly power tool is fixed to a suspension device, make sure that fixation is secure.

9. Beware of the risk of crushing or pinching if nose equipment is not fitted.

IV. REPETITIVE MOTION HAZARDS:

1. When using assembly power tool, the operator can experience discomfort in the hands, arms, shoulders, neck or other parts of the body.

2. When using tool, the operator should adopt a comfortable posture while maintaining a secure footing and avoid awkward or off balanced postures.

3. The operator should change posture during extended tasks to help avoid discomfort and fatigue.

4. If the operator experiences symptoms such as persistent or recurring discomfort, pain, throbbing, aching, tingling, numbness, burning sensations or stiffness, these warnings should not be ignored. The operator should tell the employer and consult a qualified health professional.

V. ACCESSORIES HAZARDS:

1. Disconnect tool from energy supply before changing inserted tool or accessory.

2. Use only sizes and types of accessories and consumables that are recommended. Do not use other types or sizes of accessories or consumables.

VI. WORKPLACE HAZARDS:

1. Be aware of slippery surfaces caused by use of the tool and of trip hazards caused by the air line or hydraulic hose.

2. Proceed with caution while in unfamiliar surroundings; there could be hidden hazards such as electricity or other utility lines.

3. The assembly power tool is not intended for use in potentially explosive environments.

4. Tool is not insulated against contact with electrical power.

5. Ensure there are no electrical cables, gas pipes, etc., which can cause a hazard if damaged by use of the tool.

VII. NOISE HAZARDS:

1. Exposure to high noise levels can cause permanent, disabling hearing loss and other problems such as tinnitus, therefore risk assessment and the implementation of proper controls is essential.

2. Appropriate controls to reduce the risk may include actions such as damping materials to prevent workpiece from ‘ringing’.

3. Use hearing protection in accordance with employer’s instructions and as required by occupational health and safety regulations.

4. Operate and maintain tool as recommended in the instruction handbook to prevent an unnecessary increase in the noise level.

5. Select, maintain and replace the consumable / inserted tool as recommended to prevent an unnecessary increase in noise.

6. If the power tool has a silencer, always ensure that it is in place and in good working order when the tool is being operated.

VIII. VIBRATION HAZARDS:

1. Exposure to vibration can cause disabling damage to the nerves and blood supply to the hands and arms.

2. Wear warm clothing when working in cold conditions and keep hands warm and dry.

3. If numbness, tingling, pain or whitening of the skin in the fingers or hands, stop using the tool, tell your employer and consult a physician.

4. Support the weight of the tool in a stand, tensioner or balancer in order to have a lighter grip on the tool.

IX. PNEUMATIC / PNEUDRAULIC TOOL SAFETY INSTRUCTIONS:

1. Air under pressure can cause severe injury.

2. Always shut off air supply, drain hose of air pressure and disconnect tool from air supply when not in use, before changing accessories or when making repairs.

3. Never direct air at yourself or anyone else.

4. Whipping hoses can cause severe injury, always check for damaged or loose hoses and fittings.

5. Cold air should be directed away from hands.

6. Whenever universal twist couplings (claw couplings) are used, lock pins shall be installed and whipcheck safety cables shall be used to safeguard against possible hose to hose or hose to tool connection failure.

7. Do not exceed maximum air pressure stated on tool.

8. Never carry an air tool by the hose.

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 specific instruction.

AFETY

NSTRUCTIONS

CAUTIONS: show conditions that will damage equipment and or structure.

WARNINGS: Must be understood to avoid severe personal injury.

Page 7

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

POWER SOURCE:

90‐100psi shop air

HYDRAULIC FLUID:

ATF meeting DEXRON III, DEXRON IV, MERCON, Allison C‐4 or equivalent specifications. Fire resistant hydraulic fluid may also be used, and is required to comply with OSHA regulation 1926.302 paragraph (d): "the fluid used in hydraulic power tools shall be fire resistant fluid approved under schedule 30 of the US Bureau of Mines, Department of Interior, and shall retain its operating characteristics at the most extreme temperatures to which it will be exposed."

MAX OPERATING TEMP:

125°F (51.7°C)

MAX FLOW RATE:

2.9 scfm (82.1 l/m)

MAX AIR PRESSURE:

100 psi (6.9 bar)

MIN PULL CAPACITY:

2930 lbs (13.03 kN) @ 90 psi

MIN STROKE:

.562 inches (1.43 cm)

SPEED/CYCLES:

30 per minute

WEIGHT:

5.36 lbs (2.43 kg)

OOL

PECIFICATIONS

1.780

45.21

10°

.890

22.61

3.636

92.35

6.890

175.00

4.883

124.03

.945

24.00

1.890

48.00

13.042

331.22

3.412

86.66

3.48

88.39

Page 8

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

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.

RINCIPLE

PERATION

Throttle Valve

Hydraulic Piston

PULL Piston

Relief Valve

Check Valve

Exhaust

Air Piston

Reservoir

Page 9

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

The Model 243 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-regulatorlubricator 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.

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.

9. Select proper Nose Assembly for fastener to be installed.

10. Attach Nose Assembly.

11. 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 243 pull piston. Refer to nose assembly data sheets.

Vibra-Tite is a registered trademark of ND Industries, Inc. USA

REPARATION

FOR

AINTENANCE

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 243KIT 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.

2. Check the tool and all connecting parts for damage or oil/air leaks, tighten or replace if necessary.

CAUTION: Do not use TEFLON tape on threads. Use TEFLON in stick form only: Huck P/N 503237 TEFLON is a registered

trademark of DuPont Corporation.

WARNING: Inspect tool for damage or wear before each use. Do not operate if damaged or worn, as severe personal injury may occur.

Page 10

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

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.

Please note

Failure to understand WARNINGS may cause serious personal injury.

Failure to understand CAUTIONS may cause damage to structure and Tool.

For additional safety Information, see page 4.

Read all WARNINGS and CAUTIONS prior to using your system.

PERATING

NSTRUCTIONS

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/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 first 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 efficiency and reducing downtime.

Page 11

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

(Refer to Figures 1-3 and 9 and Parts List on page

15.)

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 (70) locking it in the out position (Fig1).

4. Unscrew Cap Screws (66) with 5/32 hex key. Carefully lift Head straight up from Handle (1), remove Pull Gland Assembly (28) and Return Gland Assembly (24) from separated head and handle assemblies (Fig1).

5. Unscrew Plug (82) of return Pressure Relief Valve from front of head. Remove Spring (81), Valve Guide (79), Sleeve (80) and Steel Ball (78). A small magnet is helpful (Fig1).

6. Unscrew Bleed Plug (38). Hold over waste oil container and release fill tool slowly (Fig1).

7. Unscrew Housing/Spacer Assembly (67) from head. Remove two Springs (68). Slide Reservoir Plunger (70) from head. Remove spacer and Quad-Ring (69), a pick may be used to remove the Quad-Ring (Fig1).

8. Unscrew Plug (75) of reservoir check valve from side of head. Remove Spring (74), Check Valve Guide (73) and Stainless Steel Ball (72) (Fig1).

9. Pintail Deflector (21) can be pulled off deflector tube at rear of Piston. (Fig. 1 & 9)

10. Unscrew End Cap (21) from Head, Plug, & Seat Assy (15) with 1 9/16 open end wrench. (Fig 1 & 9)

11. 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.

12.Remove Nose Adapter (11) from front of Head, Plug & Seat Assembly (6). (Fig. 1 & 9)

13.If Seat (71) is damaged, contact your Huck representative. If Seat Assembly (76) 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) and ball cable end from Throttle Arm (65). Pull Cable Assembly (2) out of Handle (1). (Fig. 3)

15. Remove Pivot Screw (61) and Lever Guard (86) from Throttle Arm (65). Remove Throttle Arm. Pull Throttle Valve (64) out of Cylinder. Remove Spring (62) (Fig3).

16. Remove Bleed Plug (38) from handle (Fig3).

FIG. 1

FIG. 2

ISASSEMBLY

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.

FILL TOOL

112465

SPACER

RESERVOIR REMOVED

LOCK OUT POSITION

4x 69

123111-2 PISTON

123112-2

SPACER ASSEMBLY TOOL

123110-11 Main Piston Tool Assembly Kit

Page 12

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

17. Hold tool inverted in vice. Unscrew three Button Head Screws (52) with 1/8 hex key (Fig3).

18. Remove Bottom Plate (51), Gasket (54) and Muffler (50) (Fig3).

19. Remove Retaining Ring (55) from Cylinder Assembly (48) (Fig3).

20. Install Screws (52) into Cylinder Head (49). 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 (53) with a 9/16 socket and extension and with 7/64 hex key, remove Piston Screw (36).

22. Grip Locknut (53) 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 (40). Handle and Cylinder will now separate (Fig 3).

26. Push Piston Assembly (32) 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 (83) from Cylinder. Swivel Assembly may be disassembled to replace Seals (31 & 84) if necessary. (Fig. 9)

28. To remove Polyseal (45) from Gland Assembly (40), Remove Retaining Ring (46) and Spacer

FIG. 3

ISASSEMBLY

CONTINUED

56 55

28 32

39 87

SECTION A-A

Page 13

(See Figures 3 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 Backup rings in Service Parts Kit, P/N 243KIT. 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 (33) with O- ring (35) and Back-up Rings (34) in place in handle. Press in from bottom of handle

without damage to seals. (Fig. 4)

2. Place Cylinder Assembly (48) on handle with Timing Pin (87) positioned in matching hole. Assemble Gland Assembly (40) (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 (60) through Air Piston (58) from flat side. Drop Washer (59) over threaded end of Piston Rod, and screw Locknut (53) onto rod. Hold hex of rod with 9/16 wrench, and torque nut using 9/16 socket to 28 - 32 ft. lbs.

4. Push assembled Air Piston and Piston Rod into Air Cylinder and Gland Assembly (40) until it stops. Push Screw (36) with O-ring (37) in place through hydraulic Piston (33) and screw into top of Piston Rod. Hold Locknut (53) with 9/16 socket and extension and torque Screw (36) using 7/64 hex key to 55 - 60 in. lbs.

5. Push Cylinder Head (49) with O-ring (56) in place squarely into Cylinder (48). Install Retaining Ring (55). (Fig. 3)

6. Hold handle in vise with bottom facing up. Position Muffler (50) on center of Cylinder Head (49), Place Gasket (54) on Cylinder Assembly (48), place Bottom Plate (51) on top of Gasket. Secure with 3 Button Head Screws (52) using 1/8 hex key. (Fig. 3)

7. Turn tool upright. Drop Spring (62) into Throttle Valve hole in Cylinder. Push Throttle Valve (64) with O-rings (63) in place into Cylinder. (Fig. 3)

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. 3)

9. Slide Throttle Arm (65) onto ball end of Throttle Cable. Swing arm until other end fits over throttle valve.Place Lever Guard (86) over Throttle Arm and install Pivot Screw (61) through Throttle Arm . Tighten with 5/32 hex key.

10. Install Swivel Assembly (83) in Cylinder Assembly (48).

11. Reinstall Air Hose 115436 if removed.

12. If Seat Assembly (76) is being replaced push in seat and seal

assembly using soft drift. Do not damage ball seat surface. (Fig.

13.Assemble hydraulic Piston (10) with new O-ring (17) and two

new Back-up Rings (18) in place. Lubricate with LUBRIPLATE or PARKER SUPER-O-LUBE. (Fig. 9)

14. Install Nose Adapter (11) on front of head. (Use VIBRA-TITE

Huck P/N 505125 on threads). Torque to 50-60 ft. lbs.

15. Assemble Front Gland (13), Gland Cap (12), Back-up Ring (14),

O-ring (15) & Polyseal (16). Thread Piston Assembly Tool 123111-2 onto Piston (10). Slide complete Front Gland Assembly and Wiper Seal (7) over Piston Assembly Tool onto Piston. (Fig.

16.Press entire piston and gland assembly into head. Remove

Piston Assembly Tool from piston. (Fig. 7)

17.Place Seals (19) and (23) on Rear Gland (22). Push complete

assembly into head and screw in End Cap (20), and torque to 50

- 60 ft. lbs. (Fig. 9)

18.Install Quad-Ring (69) and Spacer. Slide Reservoir Plunger (70)

in. Install two Springs (68). Screw Housing/Spacer Assembly into head. (Fig. 1)

19. Push Pintail Deflector (21) onto rear of Piston (10).

20. O-ring (39) on Plug (38) and screw into Handle (1).

21.Install Pull (28) and Return (24) Gland Assemblies in handle.

Push head down on glands. Place tool in a vise Head down and install 4 Screws (66). (Fig. 3 & 9)

22.Tool is now assembled except for relief and check valves.

See fill and bleed procedure for replacing valve components.

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

FIG. 5

CAUTION: Care must be given not to scratch piston rod or cylinder during removal.

FIG. 4

Must be pres‐ sed in from bottom of handle to avoid dama‐ ging seals.

SSEMBLY

Front Gland Assembly Detail

123111-2 PISTON ASSEMBLY TOOL

18 (2)

Section Showing POLYSEAL Direction

FIG. 7

Page 14

(Figure 8)

Equipment Required:

- Shop airline with 90-100 psi max.

- Air regulator

- Fill Bottle 120337 (supplied with tool).

- Fill Tool Assy 112465

- Large flat blade screwdriver

- Stall Nut 124090

Preparation:

1. Install air regulator in airline and set pressure to 2040 psi.

2. Fill bleed bottle almost full of DEXRON III - ATF

(AUTOMATIC TRANSMISSION FLUID) , OR EQUIVALENT. Refill tool only when red line on

plunger drops below the red line on the reservoir housing or when tool is rebuilt.

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 (82) and sleeve (80) in head in Relief Valve port (front of tool).

Step 3

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.

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.

Step 5

Install fill bottle in head fill port (check Valve hole)

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 (72), Check Valve Guide (73) and Spring (74). Replace the Plug (75).

Step 9

Turn tool so front of head faces you and remove the relief valve Plug (82). Prior to removing Plug (82), it is advisable to back out setscrew inside of plug by approximately 1/2 turn counterclockwise. (See Figure 7a). This ensures that the Piston will remain in fullforward position. Install relief valve Ball (78), Guide (79), Sleeve (80) and Spring (81). Replace the Plug (82). After installing Plug (82), unscrew it approximately 1/4 turn to relieve excess hydraulic fluid, then re-tighten.

Step 10

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.

Step 11

Re-lock the fill tool. Lay tool on its left side and remove Plug (38). 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.

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

FIG. 7a

ILL

AND

LEED

WARNING: Air pressure MUST be set to 20 to 40 psi to prevent possible injury from

high pressure spray. If plug (75) is removed, fill bottle must be in place before cycling tool.

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.

Using a 3/32 Allen wrench, loosen setscrew inside Plug by approx. 1/2 turn.

SECTION A-A

from Figure 9

Page 15

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

FIG. 8

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

Remove fill tool and stall nut. Install a nose assembly and pull several fasteners to test function. (Fig. 8)

ILL

AND

LEED

CONTINUED

124090 STALL NUT

RETAINING NUT

FILL TOOL 112465

(IN LOCK-OUT POSITION)

INSTALL FILL & BLEED BOTTLE HERE (CHECK VALVE HOLE)

RED LINE INDICATOR

PLUG

FILL POINT

120337 FILL BOTTLE ASSY

INCLUDES: 120336 FILL BOTTLE 120004 CAP

Page 16

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

FIG. 9

SSEMBLY

RAWING

31 (2)

SECTION C-C

(2)

VIEW D-D

ITEM 24 DETAIL

(RETURN GLAND ASSY)

ITEM 28 DETAIL

(PULL GLAND ASSY)

26 (2)

27 (2)

66 (4)

67 68 (2)

See Detail

52 (3)

See Detail

SECTION A-A

46 45

ITEM 40 DETAIL

(GLAND ASSY)

ITEM 32 DETAIL

(PISTON ASSY)

34 (2) 35

REF

SECTION B-B

7777

(2)

Page 17

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

1 125550 Handle 1 2 116404-1 Cable Assembly 1 3 505496 Dowel Pin 1 4 500621 Pin 1 5 124333-1 Trigger 1 6 125535 Head, Seat, & Plug Assembly 1 7 505817 Wiper Seal 1 8 111795 Retaining Nut 1 9 120588 Stop 1 10 125885 Piston 1 11 125537 Nose Adapter 1 12 122432 Gland Cap 1 13 125538 Front Gland 1 14 501113 Back-up Ring 1 15 500819 O-Ring 1 16 505818 Polyseal 1 17 507401 O-Ring 1 18 501142 Back-up Ring 2 19 507400 Polyseal 1 20 125545 End Cap 1 21 124211 Pintail Deflector 1 22 125543 Rear Gland 1 23 500820 O-Ring 1 24 125555 Return Gland Assembly 1 25 125554 Gland Housing 1 26 500776 O-Ring 3 27 501082 Back-up Ring 6 28 125553 Pull Gland Assembly 1 29 125552 Gland Housing 1 30 501085 Back-up Ring 1 31 500779 O-Ring 3 32 118865 Piston Assembly 1 33 117774 Piston 1 34 501084 Back-up Ring 2 35 503768 O-Ring 1 36 117773 Screw 1 37 500773 O-Ring 1 38 100309 Plug 2 39 505438 O-Ring 3 40 125557 Gland Assembly 1 41 126311 Gland 1 42 123904 Spacer 1 43 500786 O-Ring 1 44 501074 QUAD Ring 1 45 506611 Polyseal 1

46 505939 Retaining Ring 1 47 500812 O-Ring 1 48 125471 Cylinder Assembly 1 49 111959-2 Cylinder Head 1 50 115554-2 Muffler 1 51 116585-2 End Cap 1 52 504127 Screw 3 53 505420 Locknut 1 54 126941 Gasket 1 55 506878 Retaining Ring 1 56 500864 O-Ring 1 57 501451 QUAD Ring 1 58 123753-1 Piston 1 59 506493 Washer 1 60 125561 Piston Rod 1 61 125118 Pivot Screw 1 62 116272 Spring 1 63 507396 O-Ring 3 64 125467-2 Throttle Valve 1 65 123754-1 Throttle Arm 1 66 500062 Screw 4 67 112403 Housing & Spacer Assembly 1 68 505864 Spring 2 69 501408 QUAD Ring 1 70 112405 Reservoir Plunger 1 71 111139 Seat 1 72 502929 Ball 3/16” 1 73 111067 Guide 1 74 100874 Spring 1 75 111068 Plug 1 76 126134 Seat Assembly 1 77 505446 O-Ring 2 78 502506 Ball 5/32” 1 79 120128 Ball Guide 1 80 120127 Sleeve 1 81 507403 Spring 1 82 114530 Plug 1 83 507164 Swivel Assembly 1 84 500778 O-Ring 1 85 506576 Plug & Gasket Assembly 1 86 125116 Guard 1 87 505496 Timing Pin 1

ITEM PART NO. DESCRIPTION QTY. ITEM PART NO. DESCRIPTION QTY.

ARTS

IST

IST (Refer to Figure 9)

Page 18

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

Always check out the simplest possible cause of a malfunction first. For example, an air hose not connected. Then proceed logically, eliminating each possible cause until the cause is located. Where possible, substitute known good parts for suspected bad parts. Use TROUBLESHOOTING 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 (63), worn or damaged. c) Throttle valve Cable Assembly (2) is broken.

2 Tool does not complete fastener installation

and break pintail.

a) Air pressure too low b) Air Piston Quad-Ring (57) 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 (68) 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 (8) 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 (76), O-

ring (26), Back-up Rings (27), Steel Ball (78)

and Valve Spring (81). Replace if necessary.

c) Worn or damaged Piston Assembly (32);

Inspect O-ring (35), O-ring (37) and Back-up

Rings (34). Replace if necessary.

5 Hydraulic fluid exhausts with air or leaks at

base of handle.

a) Worn or damaged Gland Assembly (40);

Inspect Polyseal (45), O-rings (43 & 47) and

Quad-Ring (44). Replace if necessary.

6. Hydraulic fluid leaks at rear of Pull Piston (10)

a) Worn or damaged Rear Gland (22), inspect

Polyseal (19) and O-ring (23). Replace if necessary.

7. Hydraulic fluid leaks at front of Pull Piston (10).

a) Worn or damaged Front Gland (13); Inspect

Polyseal (16), O-ring (15) and Back-up Ring (14). Replace if necessary.

8. Pull Piston (10) will not return.

a) Throttle Valve (64) stuck; Lubricate O-rings

(63).

b) Throttle Arm (65), Cable Assembly (2) or

Trigger (5) binding.

9. Air leaks at air Cylinder Head (49).

a). Worn or damaged O-ring (56). Replace if

necessary.

CCESSORIES

Fill and Bleed Bottle (Fig.8) - 120337

Fill Tool Assy for reservoir (Fig.8) - 112465

Stall Nut (Fig.8) - 124090

Seat Removal Tool - 126136

Air Hose - 115436

Pintail Bottle Attachment Kit - 126367

Pintail Collection Bag - 125655

Pintail Tube (for -05 fastener) - 100534-1

Retaining Nut (for

“Jiffy” style noses) - 125412

Piston Assembly Tool Kit - 123110-11

Includes:

Piston Assembly Tool (Fig. 2) - 123111-2 Spacer (Fig. 2) - 123112-2

Service Tool Kit - 120352-244

Includes:

Fill and Bleed Bottle (Fig.8) - 120337 Fill Tool for reservoir (Fig.8) - 112465 Stall Nut (Fig.8) - 124090

Service Kit - 243KIT

Head Assy to convert to 243OS - 125952

ROUBLESHOOTING

Page 19

Model 243 Pneudraulic Installation Tool

(HK1051)

Alcoa Fastening Systems

IMITED

ARRANTIES

TOOLING WARRANTY:

Huck warrants that tooling and other items (excluding fasteners, and hereinafter referred as "other items") manufactured by Huck shall be free from defects in workmanship and materials for a period of ninety (90) days from the date of original purchase.

WARRANTY ON "NON STANDARD OR CUSTOM

MANUFACTURED PRODUCTS":

With regard to non-standard products or custom manufactured products to customer's specifications, Huck warrants for a period of ninety (90) days from the date of purchase that such products shall meet Buyer's specifications, be free of defects in workmanship and materials. Such warranty shall not be effective with respect to non-standard or custom products manufactured using buyer-supplied molds, material, tooling and fixtures that are not in good condition or repair and suitable for their intended purpose.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. HUCK MAKES NO OTHER WARRANTIES AND EXPRESSLY DISCLAIMS ANY OTHER WARRANTIES, INCLUDING IMPLIED WARRANTIES AS TO MERCHANTABILITY OR AS TO THE FITNESS OF THE TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS FOR ANY PARTICULAR PURPOSE AND HUCK SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING FROM THE USE OF SUCH TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS OR BREACH OF WARRANTY OR FOR ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Huck's sole liability and Buyer's exclusive remedy for any breach of warranty shall be limited, at Huck's option, to replacement or repair, at FOB Huck's plant, of Huck manufactured tooling, other items, nonstandard or custom products found to be defective in specifications, workmanship and materials not otherwise the direct or indirect cause of Buyer supplied molds, material, tooling or fixtures. Buyer shall give Huck written notice of claims for defects within the ninety (90) day warranty period for tooling, other items, nonstandard or custom products described above and Huck shall inspect products for which such claim is made.

TOOLING, PART(S) AND OTHER ITEMS NOT

MANUFACTURED BY HUCK:

HUCK MAKES NO WARRANTY WITH RESPECT

TO THE TOOLING, PART(S) OR OTHER ITEMS MANUFACTURED BY THIRD PARTIES. HUCK EXPRESSLY DISCLAIMS ANY WARRANTY EXPRESSED OR IMPLIED, AS TO THE CONDITION, DESIGN, OPERATION, MERCHANTABILITY OR FITNESS FOR USE OF ANY TOOL, PART(S), OR OTHER ITEMS THEREOF NOT MANUFACTURED BY HUCK. HUCK SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING FROM THE USE OF SUCH TOOLING, PART(S) OR OTHER ITEMS OR BREACH OF WARRANTY OR FOR ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

The only warranties made with respect to such tool, part(s) or other items thereof are those made by the manufacturer thereof and Huck agrees to cooperate with Buyer in enforcing such warranties when such action is necessary.

Huck shall not be liable for any loss or damage resulting from delays or nonfulfillment of orders owing to strikes, fires, accidents, transportation companies or for any reason or reasons beyond the control of the Huck or its suppliers.

HUCK INSTALLATION EQUIPMENT:

Huck International, Inc. reserves the right to make changes in specifications and design and to discontinue models without notice.

Huck Installation Equipment should be serviced by trained service technicians only.

Always give the Serial Number of the equipment when corresponding or ordering service parts.

Complete repair facilities are maintained by Huck International, Inc. Please contact one of the offices listed below.

Eastern One Corporate Drive Kingston, New York 12401-0250 Telephone (845) 331-7300 FAX (845) 334-7333

Outside USA and Canada Contact your nearest Huck International Office, see back cover.

In addition to the above repair facilities, there are Authorized Tool Service Centers (ATSC's) located throughout the United States. These service centers offer repair services, spare parts, Service Parts Kits, Service Tools Kits and Nose Assemblies. Please contact your Huck Representative or the nearest Huck office listed on the back cover for the ATSC in your area.

Page 20

Americas

Alcoa Fastening Systems

Aerospace Products Tucson Operations

3724 East Columbia Tucson, AZ 85714 800‐234‐4825 520‐747‐9898 FAX: 520‐748‐2142

Alcoa Fastening Systems

Aerospace Products Carson Operations

PO Box 5268 900 Watson Center Rd. Carson, CA 90749 800‐421‐1459 310‐830‐8200 FAX: 310‐830‐1436

Alcoa Fastening Systems

Industrial Products Waco Operations

PO Box 8117 8001 Imperial Drive Waco, TX 76714‐8117 800‐388‐4825 254‐776‐2000 FAX: 254‐751‐5259

Alcoa Fastening Systems

Industrial Products Kingston Operations

1 Corporate Drive Kingston, NY 12401 800‐278‐4825 845‐331‐7300 FAX: 845‐334‐7333

Alcoa Fastening Systems

Industrial Products Latin America Operations

Avenida Parque Lira. 79‐402 Tacubaya Mexico, D.F. C.P. 11850 FAX: 525‐515‐1776 TELEX: 1173530 LUKSME

Far East

Alcoa Fastening Systems

Industrial Products Australia Operations

14 Viewtech Place Rowville, Victoria Australia 3178 03‐764‐5500 Toll Free: 008‐335‐030 FAX: 03‐764‐5510

Europe

Alcoa Fastening Systems

Industrial Products United Kingdom Operations

Unit C, Stafford Park 7 Telford, Shropshire England TF3 3BQ 01952‐290011 FAX: 0952‐290459

Alcoa Fastening Systems

Aerospace Products France Operations

Clos D’Asseville BP4 95450 Us Par Vigny France 33‐1‐30‐27‐9500 FAX: 33‐1‐34‐66‐0600

A Global Organization

Alcoa Fastening Systems (AFS) maintains company offices throughout the United States and Canada, with subsidiary offices in many other countries. Authorized AFS distributors are also located in many of the world’s

Industrial and Aerospace centers, where they provide a ready source of AFS fasteners, installation tools, tool parts, and application assistance.

For The Long Haul, The Future of Fastening Technology, The Future of Assembly Technology, The Future of Tooling Technology, and Tools of Productivity are service marks of Huck International. Huck provides technical assistance regarding the use and application of Huck fasteners and tooling.

NOTICE: The information contained in this publication is only for general guidance with regard to properties of the products shown

and/or the means for selecting such products, and is not intended to create any warranty, express, implied, or statutory; all warranties are contained only in Huck’s written quotations, acknowledgements, and/or purchase orders. It is recommended that the user secure specific, up‐ to‐date data and information regarding each application and/or use of such products.

HWB898 1003‐5M

1 Corporate Drive, Kingston, NY 12401 • Tel: 800‐431‐3091 • Fax: 845‐334‐7333 • www.alcoafasteningsystems.com

One Great Connection

Alcoa Fastening Systems world-wide locations:

For the Long Haul

™

Certified to

ISO 9001:2008

Industrial Products

Certified to

ISO 14001:2004

Industrial Products