INSTRUCTION MANUAL

255
PNEUDRAULIC INSTALLATION TOOL

(Shown without silicone boot.)

04-01-2013
HK1014
255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

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255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

C ONTENTS
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

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 255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems
S AFETY I NSTRUCTIONS
8. There is possibility of forcible ejection of pintails or spent mandrels from
GLOSSARY OF TERMS AND SYMBOLS: front of tool.
III. OPERATING HAZARDS:
- Product complies with requirements set forth by the 1. Use of tool can expose the operator’s hands to hazards including:
relevant European directives. crushing, impacts, cuts, abrasions and heat. Wear suitable gloves to
protect hands.
2. Operators and maintenance personnel shall be physically able to handle
- READ MANUAL prior to using this equipment. 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.
- EYE PROTECTION IS REQUIRED while using this 4. Maintain a balanced body position and secure footing.
equipment. 5. Release trigger or stop start device in case of interruption of energy
supply.
- HEARING PROTECTION IS REQUIRED while using this 6. Use only fluids and lubricants recommended by the manufacturer.
7. Avoid unsuitable postures, as it is likely for these not to allow
equipment. counteracting of normal or unexpected tool movement.
8. If the assembly power tool is fixed to a suspension device, make sure that
WARNINGS: Must be understood to avoid fixation is secure.
9. Beware of the risk of crushing or pinching if nose equipment is not fitted.
severe personal injury.
IV. REPETITIVE MOTION HAZARDS:
1. When using assembly power tool, the operator can experience discomfort
CAUTIONS: show conditions that will in the hands, arms, shoulders, neck or other parts of the body.
damage equipment and or structure. 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
Notes: are reminders of required procedures. discomfort and fatigue.
Bold, Italic type and underlining: emphasizes a specific instruction. 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
I. GENERAL SAFETY RULES: operator should tell the employer and consult a qualified health
1. A half hour long hands-on training session with qualified personnel is professional.
recommended before using Huck equipment.
2. Huck equipment must be maintained in a safe working condition at all V. ACCESSORIES HAZARDS:
times. Tools and hoses should be inspected at the beginning of each 1. Disconnect tool from energy supply before changing inserted tool or
shift/day for damage or wear. Any repair should be done by a qualified accessory.
repairman trained on Huck procedures. 2. Use only sizes and types of accessories and consumables that are
3. For multiple hazards, read and understand the safety instructions before recommended. Do not use other types or sizes of accessories or
installing, operating, repairing, maintaining, changing accessories on, or consumables.
working near the assembly power tool. Failure to do so can result in
serious bodily injury. VI. WORKPLACE HAZARDS:
4. Only qualified and trained operators should install, adjust or use the 1. Be aware of slippery surfaces caused by use of the tool and of trip
assembly power tool. hazards caused by the air line or hydraulic hose.
5. Do not modify this assembly power tool. This can reduce effectiveness of 2. Proceed with caution while in unfamiliar surroundings; there could be
safety measures and increase operator risk. hidden hazards such as electricity or other utility lines.
6. Do not discard safety instructions; give them to the operator. 3. The assembly power tool is not intended for use in potentially explosive
7. Do not use assembly power tool if it has been damaged. environments.
8. Tools shall be inspected periodically to verify all ratings and markings 4. Tool is not insulated against contact with electrical power.
required, and listed in the manual, are legibly marked on the tool. The 5. Ensure there are no electrical cables, gas pipes, etc., which can cause a
employer/operator shall contact the manufacturer to obtain replacement hazard if damaged by use of the tool.
marking labels when necessary. Refer to assembly drawing and parts list
for replacement. VII. NOISE HAZARDS:
9. Tool is only to be used as stated in this manual. Any other use is 1. Exposure to high noise levels can cause permanent, disabling hearing
prohibited. loss and other problems such as tinnitus, therefore risk assessment and
10. Read MSDS Specifications before servicing the tool. MSDS the implementation of proper controls is essential.
specifications are available from the product manufacturer or your Huck 2. Appropriate controls to reduce the risk may include actions such as
representative. damping materials to prevent workpiece from ‘ringing’.
11.Only genuine Huck parts shall be used for replacements or spares. Use 3. Use hearing protection in accordance with employer’s instructions and as
of any other parts can result in tooling damage or personal injury. required by occupational health and safety regulations.
12.Never remove any safety guards or pintail deflectors. 4. Operate and maintain tool as recommended in the instruction handbook
13.Never install a fastener in free air. Personal injury from fastener ejecting to prevent an unnecessary increase in the noise level.
may occur. 5. Select, maintain and replace the consumable / inserted tool as
14.Where applicable, always clear spent pintail out of nose assembly before recommended to prevent an unnecessary increase in noise.
installing the next fastener. 6. If the power tool has a silencer, always ensure that it is in place and in
15.Check clearance between trigger and work piece to ensure there is no good working order when the tool is being operated.
pinch point when tool is activated. Remote triggers are available for
hydraulic tooling if pinch point is unavoidable. VIII. VIBRATION HAZARDS:
16.Do not abuse tool by dropping or using it as a hammer. Never use 1. Exposure to vibration can cause disabling damage to the nerves and
hydraulic or air lines as a handle or to bend or pry the tool. Reasonable blood supply to the hands and arms.
care of installation tools by operators is an important factor in maintaining 2. Wear warm clothing when working in cold conditions and keep hands
tool efficiency, eliminating downtime, and preventing an accident which warm and dry.
may cause severe personal injury. 3. If numbness, tingling, pain or whitening of the skin in the fingers or hands,
17.Never place hands between nose assembly and work piece. Keep hands stop using the tool, tell your employer and consult a physician.
clear from front of tool. 4. Support the weight of the tool in a stand, tensioner or balancer in order to
18.Tools with ejector rods should never be cycled with out nose assembly have a lighter grip on the tool.
installed.
19.When two piece lock bolts are being used always make sure the collar IX. PNEUMATIC / PNEUDRAULIC TOOL SAFETY INSTRUCTIONS:
orientation is correct. See fastener data sheet for correct positioning. 1. Air under pressure can cause severe injury.
2. Always shut off air supply, drain hose of air pressure and disconnect tool
II. PROJECTILE HAZARDS: from air supply when not in use, before changing accessories or when
1. Risk of whipping compressed air hose if tool is pneudraulic or pneumatic. making repairs.
2. Disconnect the assembly power tool from energy source when changing 3. Never direct air at yourself or anyone else.
inserted tools or accessories. 4. Whipping hoses can cause severe injury, always check for damaged or
3. Be aware that failure of the workpiece, accessories, or the inserted tool loose hoses and fittings.
itself can generate high velocity projectiles. 5. Cold air should be directed away from hands.
4. Always wear impact resistant eye protection during tool operation. The 6. Whenever universal twist couplings (claw couplings) are used, lock pins
grade of protection required should be assessed for each use. shall be installed and whipcheck safety cables shall be used to safeguard
5. The risk of others should also be assessed at this time. against possible hose to hose or hose to tool connection failure.
6. Ensure that the workpiece is securely fixed. 7. Do not exceed maximum air pressure stated on tool.
7. Check that the means of protection from ejection of fastener or pintail is in 8. Never carry an air tool by the hose.
place and operative.
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255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

S PECIFICATIONS
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)
7.091
180.11

MAX FLOW RATE:

.959
11.5 scfm (325.64 l/m) 4°
24.36

HUCK 255

ø 1.920
MAX AIR PRESSURE: 48.77

100 psi (6.9 bar)

inches
mm
MIN PULL CAPACITY:
7500 lbs (34.47 kN) @ 90 psi
14.86
377.59

MIN STROKE:
.625 inches (1.59 cm)

6.020
SPEED/CYCLES: 153.00

30 per minute

WEIGHT:
8.8 lbs (3.99 kg)
ø 4.610
118.00

3.957
100.51

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255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

P RINCIPLE OF O PERATION

PULL PISTON

RELIEF
VALVE CHECK
VALVE

HYDRAULIC
PISTON

THROTTLE
VALVE

RESERVOIR

EXHAUST AIR PISTON

PULL RETURN

When the trigger is depressed, the throttle valve When fastener installation is completed, the trigger
moves to down position, and pressurized air is is released. Air pressure, with the assistance of a
directed to the bottom of the air piston, causing the spring, causes the throttle valve to return to its up
piston to move upward. The air above the piston is position. Pressurized air is re‐directed to the top of
exhausted and directed through the center of the the air piston, causing the piston to move
throttle valve and out the bottom of the tool. The downward. The air from below the piston is
air piston has a rod and a hydraulic piston attached. exhausted through bottom of tool. The rod and
When the air piston rod moves upward, a column of hydraulic piston move downward, hydraulic pressure
pressurized fluid is forced into the head, which is reversed and the pull piston is returned forward.
moves the pull piston back. The attached nose The return pressure relief valve protects the tool
assembly moves with the pull piston to start fastener against pressure spikes. The reservoir replenishes
installation. the hydraulic system as needed.

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255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

P REPARATION FOR U SE
The Model 255 Installation Tool is shipped with a plastic 7. Disconnect air hose from tool.
plug in the air inlet connector. The connector has 1/4- 8. Remove Retaining Nut and Stop.
18 female pipe threads to accept the air hose fitting. 9. Select proper Nose Assembly for fastener to be
Quick disconnect fittings and 1/4” inside diameter air installed.
hose are recommended. An air supply of 90-100 psi 10. Screw Collet Assembly (including lock collar and
capable of 11.5 CFM must be available. Air supply shim if applicable) onto Spindle holding Pull Piston
should be equipped with a filter-regulator-lubricator unit. (11) with 3/8 hex key. (Wrench Tight)
11. Slide Anvil over Collet Assembly and into
1. Remove plastic shipping plug from Air Inlet counterbore.
Connector and put in a few drops of Automatic 12. Slide Stop and Retaining Nut over Anvil and screw
Transmission Fluid, DEXRON III, or equivalent. Nut onto Head.
2. Screw quick disconnect fitting into Air Inlet 13. Connect air hose to tool and install fastener(s) in
Connector. test plate of proper thickness with proper size holes.
CAUTION: Do not use TEFLON tape on Inspect fastener(s).
threads. Use TEFLON in stick form only:
Huck P/N 503237 TEFLON is a registered NOTES:
trademark of DuPont Corporation. 1 Air quick disconnect fittings and air hoses are not
available from Huck International, Inc.
3. Set air pressure on regulator to 90-100 psi. 2 Vibra-Tite (Huck P/N 505125) should be used on
4. Attach optional Air Hose (38), supplied with tool, to collet threads for nose assemblies without lock
air inlet connector. collars. All other noses should be staked.
5. Connect air hose to tool. Vibra-Tite is a registered trademark of ND Industries, Inc. USA
6. Cycle tool a few times by depressing and releasing
trigger.

M AINTENANCE
GENERAL DAILY
1. The efficiency and life of any tool depends upon 1. If a Filter-Regulator-Lubricator unit is not being used,
proper maintenance. Regular inspection and uncouple air disconnects and put a few drops of
correction of minor problems will keep tool operating Automatic Transmission Fluid or light oil into the air
efficiently and prevent downtime. The tool should be inlet of the tool. If the tool is in continuous use, put a
serviced by personnel who are thoroughly familiar few drops of oil in every two to three hours.
with how it operates. 2. Bleed the air line to clear it of accumulated dirt or
2. A clean, well-lighted area should be available for water before connecting air hose to the tool.
servicing the tool. Special care must be taken to 3. Check all hoses and couplings for damage or air
prevent contamination of pneumatic and hydraulic leaks, tighten or replace if necessary.
systems. 4. Check the tool for damage or air/hydraulic leaks,
3. Proper hand tools, both standard and special, must tighten or replace if necessary.
be available. 5. Check the nose assembly for tightness or damage,
4. All parts must be handled carefully and examined for tighten or replace if necessary.
damage or wear. Always replace Seals, when tool is 6. Check oil level in tool reservoir, replenish if
disassembled for any reason. Components should be necessary.
disassembled and assembled in a straight line
without bending, cocking, or undue force.
Disassembly and assembly procedures outlined in
WEEKLY
this manual should be followed. 1. Disassemble and clean nose assemblies and
5. Service Parts Kit 255KIT includes consumable parts reassemble per applicable.
and should be available at all times. Other components,
as experiece dictates, should also be available. 2. Check the tool and all connecting parts for damage or
oil/air leaks, tighten or replace if necessary.
WARNING: Inspect tool for damage or
wear before each use. Do not operate if
damaged or worn, as severe personal
injury may occur.

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255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

O PERATING I NSTRUCTIONS

Read all WARNINGS and CAUTIONS prior to using your system.

LOCKBOLT® Fastener installation: Blind Fastener Installation:

WARNING: Do not pull on a pin without a WARNING: Do not pull on a fastener’s pin
collar. The pin will eject with velocity and without first placing fastener In a work
force when the pintail breaks off. This may piece. The fastener will eject forcibly when
cause serious injury. the pintail breaks off. This may cause
serious Injury.
CAUTION: Remove excess gap from
between the sheets. This permits enough
Remove excess gap from between the sheets to
pintail to emerge from collar for ALL jaw
teeth to engage with pintail. If ALL teeth do permit correct fastener installation. Fastener may be
not engage properly, jaws will be placed in work hole or in end of nose assembly.
stripped/damaged. 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
Place pin in work hole and place collar over
and nose assembly are ready for next fastener
pin. See WARNING. (If Collar has only one tapered
installation cycle.
end, that end must be out toward tool, not next to
sheet.) Hold pin and push nose assembly onto pin CAUTION: To avoid structural and Tool
protruding through collar until nose assembly anvil damage, be sure enough clearance is
touches collar. Depress trigger and hold depressed allowed for nose assembly at full stroke.
until collar is swaged and pintail breaks. Release Do not abuse the tool by dropping it, using
trigger and tool will go into return stroke. The tool it as a hammer or otherwise causing
and nose assembly are ready for the next fastener unnecessary wear and tear. Reasonable
care of installation tools by operators is an
installation cycle.
Important factor in maintaining tool
efficiency and reducing downtime.

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.

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255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

D ISASSEMBLY
WARNING: Be sure air hose is by using the following procedure.
disconnected from tool before cleaning, or NOTE: If seat is taken out it can not be reused, it
performing maintenance. Severe personal must be replaced. (Fig. 9)
injury may occur if air hose is not
disconnected. 10. (Seat 88 removal) Note: all parts in the reservoir
check valve must be removed before Plug (70) can
For component identification and Parts list, refer be removed. Unscrew Plug (74), insert a #10
to Figures 1 thru 4 and 9. screw in the thread of Plug (70), and pull to
remove. Using a small drift and hammer, from the
NOTE: The following procedure is for complete rear side of the head, drive Seat (88) out towards
disassembly of tool. Disassemble only components the front of the head. (Fig. 9)
necessary to replace damaged O-rings, Quad rings,
Back-up rings, and worn or damaged components. 11. Pintail Deflector (21) can be pulled off barbed end
Always use soft jaw vice to avoid damage to tool. at rear of Pull Piston (11).

1. Disconnect air hose from tool. 12. Unscrew End Cap (20) from Head (89) with 1 9/16
open end wrench. (Fig. 9)
2. Remove nose assembly. Follow instructions on
Nose Assembly Data sheet. 13. Place Spacer (123112-1) on Pull Piston (11), and
screw Assembly/disassembly Bullet (123111-1)
3. Insert Fill Tool P/N 112465 through reservoir onto piston. Tap or press piston assembly out of
housing and screw into Reservoir Plunger (79) head.
locking it in the out position. (Fig. 1) NOTE: This will push out front and rear gland
assemblies and wiper and wiper housing. (Fig. 2)
4. Unscrew Cap Screws (69) with 5/32 hex key.
Carefully lift Head (89) straight up from Handle (1), 14. Remove Screw (67) from Throttle Arm (66).
remove Pull Gland (90) and Return Gland (22) Remove throttle arm. Pull Throttle Valve (36) out of
from separated assemblies. Remove seals from cylinder. Remove Spring (40). (Fig. 9)
glands. (Fig. 1)

5. Unscrew Plug (83) of return Pressure LOCK-OUT POSITION FIG. 1

Relief Valve from front of head. Remove
Spring (84), Valve Guide (86), Sleeve FILL TOOL
112465
(85) and Steel Ball (87). A small magnet
is helpful. (Fig. 1)

6. Unscrew Bleed Plug (64). Hold over HUCK 255

SPACER
waste oil container and release fill tool
slowly. (Fig. 1)
64
7. Unscrew Reservoir Housing (81) from
81 80 82(2) 79
head. Remove two Springs (82). Slide
Reservoir Plunger (79) from head.
Remove spacer and Quad Ring (80). A 21 20 89
pick may be used to remove the quad
ring. (Fig. 1) 70
74 84 83
8. Unscrew Plug (71) of reservoir check
Valve from side of head. Remove Spring
(75), check Valve Guide (76) and 71
Stainless Steel Ball (77). (Fig. 1) 90 85 87 86
75 76 77 22
9. If check Valve Seat (78) is damaged 69(4)
contact your Huck representative. If Seat
(88) is damaged it can be removed 1
(through the front of the tool head only)
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255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

D ISASSEMBLY ( CONTINUED )
15. With a small punch and hammer, drive Roll Pin (5)
that retains the trigger from Handle (1). Remove
FIG. 3 45
trigger pin (4). Remove ball end of Cable (2) from
42
throttle arm (66), and pull cable out of handle.
(Figure 9) 46
43
16. Remove Bleed Plug (64) from handle. (Fig. 1) 44
47
17. Hold tool inverted in vice. Unscrew three Button
49
Head Screws (45) with 1/8 hex key. (Fig. 3)
48
18. Remove Muffler End Cap (42), Bottom Exhaust 51
Gasket (46), Muffler (43) and O-ring (44). (Fig. 3) 50
52
19. Remove Retaining Ring (47) from Cylinder
Assembly (53). (Fig. 3) NOTE: Tap cylinder head 53
down into cylinder for easier removal of retaining
ring.

20. Screw Button Head Screws (45) into Cylinder

Head (49). Carefully pry under screws to remove
cylinder head.

21. Push air piston all the way down in cylinder, and lay
54
tool on its side. Hold Self-locking Nut (41) with a
9/16 socket and extension and with 7/64 hex key,
remove piston Screw (32). (Fig. 4 & 9)
1
22. Turn cylinder and handle upside down and secure
in a vise.

23. Grip Self-locking Nut (41) under Air Piston (51) with
pliers and pull piston and rod assembly from
handle and cylinder assembly. (Fig. 3 & 4)

CAUTION: Care must be given not to scratch

piston rod or cylinder during removal.

FIG. 2
15 14 24. With a 1 3/8 socket and extension, remove Gland
92 Assembly (54). Handle and cylinder will now
separate. (Fig. 3)
91
10 (Note
9 orientation 25. Push Hydraulic Piston (31) out of handle. Push out
of polyseal)
from top to bottom.

123111-1 CAUTION: A plastic or wooden drift must be

ASSEMBLY used to avoid damaging the handle bore.
BULLET

26. To remove Polyseal (61) from Gland Assembly

(54), remove Retaining Ring (59) and Spacer (60).
123112-1 HUCK 255 (Fig. 9)
SPACER

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255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems
A SSEMBLY
(Refer to Figures 1 thru 5 and 9.) Clean components with place into cylinder. (Fig. 9)
mineral spirits, or similar solvent. Inspect for wear or damage
and replace as necessary. Replace all seals of disassembled 8. Assemble Trigger (3) Cable (2) and Trigger Pin (4), and slide
components. Use O-rings, Quad rings and Back-up rings in cable into Handle (1). Align hole in trigger with hole in handle
Service Parts Kit 255KIT Smear LUBRIPLATE 130AA or and install Roll Pin (5) with a hammer and punch. (Fig. 9)
PARKER-O-LUBE on O-rings, Quad rings, Back-up rings and
mating parts to ease assembly. Assemble tool giving care not to 9. Slide Throttle Arm (66) onto ball end of Throttle Cable. Swing
damage O-rings, Quad rings, or Back-up rings. arm until other end fits over throttle valve. Push Screw (67)
through Throttle Arm. Tighten with 5/32 hex key.
1. Holding handle inverted in a vice, place Cylinder (53) on
handle with Timing Pin positioned in matching hole. 10. Reinstall Air Hose Assembly (38) if it was removed.
Assemble Gland Assembly (54), screw it into handle, and
torque to 75-80 ft. lbs. using 1 3/8 socket wrench. 11. (If seat (88) is being replaced) Push Plug (70) (with O-ring
72 & Back-up Ring 25 in place) into head. Install Screw
2. Push Air Piston/Rod assembly with Quad Ring (50) in place (74). (Fig. 9)
into Air Cylinder until it bottoms at top of Cylinder. (Fig. 3)
12. Install O-ring (72) and Back-up rings (25) onto seat. Drive
3. Turn tool upright. Install Hydraulic Piston Assembly (31) (with seat and seal assembly in using soft drift taking care not to
O-ring (33) and Back-up Rings (27) in place) in handle. Press damage ball seat surface. (Fig. 1 & 9)
in from top of handle without damaging seals. (Fig. 4)
4. Push Screw (32) with O-ring (35) in place through Hydraulic 13. Assemble Pull Piston (11) with new Seals (12 & 13).
Piston (34) and screw into top of piston rod. Hold Self- Lubricate with LUBRIPLATE or PARKER SUPER-O-LUBE.
FIG. 4 31 14. Thread Assembly Bullet (123111-1) onto Pull Piston (11) and
Piston push entire assembly into head. (Fig. 2) NOTE: Spacer
Assembly
(123112-1) is not needed for this procedure.

15. Push Front Gland (92) with O-ring (14), Back-up Ring (15),
Polyseal (10), Wiper Housing (91) and Wiper Seal (9) in
place onto Pull Piston (11). (Fig. 2)

16. Install O-rings (16 & 18) and Back-up Rings (17 & 19) on
Rear Gland (93). Push complete assembly into head,
screw in End Cap (20) and torque Cap to 55-60 ft.lbs.

17. Install O-ring (72) & Back-up Ring (25) on Plug (83). Install
Ball (87), Valve Guide (86), Sleeve (85), Spring (84) and
Plug (83) into head. (Fig. 1 & 9)

18. Install O-ring (65) on Plug (71). Install Ball (77), Guide (76),
Spring (75) and Plug into head.

41 19. Push Pintail Deflector (21) onto end of Pull Piston (11).

20. Place O-ring (65) on Bleed Plug (64) and screw assembly
into Handle (1). (Fig. 9)

21. Install O-rings (24 & 30) & Back-up Rings (25 & 29) on
locking Nut (41) with 9/16 socket and extension and torque Pull Gland (28), O-rings (24 & 26) and Back-up Rings (25
Screw (32) using 7/64 hex key to 55-60 in. lbs. Torque Nut & 27) on Return Gland (23), and push Gland Assemblies
(41) to 28-32 ft. lbs. (22 & 90) into handle. Push Head (89) down on glands.
Place tool in a vise, 89 FIG. 5
5. Hold handle in vise with bottom facing up. Push Cylinder head down, and install
Head (49) with O-ring (48) in place squarely into cylinder. 4 Screws (69) and
Install Retaining Ring (47). (Figs. 3 & 9) torque to 170 inch
pounds. (Fig. 5)
6. Position O-ring (44) and Muffler (43) on center of Cylinder
Head (49). Place Gasket (46) on Cylinder Assembly (53). 22. Tool is now assembled 22 90
NOTE: Lip must face Muffler End Cap (42). Place Muffler and ready for Fill and
End Cap (42) on top of Gasket (46), and secure with 3 Button Bleed. 1 69(4)
Head Screws (45) using 1/8 hex key. (Fig. 3)

7. Turn tool upright. Drop Spring (40) into Throttle valve hole in
cylinder. Push Throttle Valve (36) with O-rings (37 & 39) in
11
255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

F ILL AND B LEED

Equipment Required: Step 2
- Shop airline with 90 - 100 psi max. Remove Plugs (83) and (71) and all guides, springs
- Air regulator and balls from ports in head. Reinstall Plug (83) in
- Fill bottle, 120337, (supplied with tool). head in Relief Valve port (front of tool). (Fig. 7 & 8).
- Large flat blade screwdriver
- Optional Stall Nut 120824 Step 3
- Nose assembly FIG. 6 Screw retaining nut onto head assembly. Screw Stall
- Fasteners (Optional) FILL Nut (optional see note:) onto Piston and tighten to
Preparation: POINT ensure full thread engagement. Back off retaining nut
1. Install air regulator in until it engages stall nut. Check Piston location. Piston
airline and set pressure to must be all the way forward and locked with stall nut
20-40 psi. 120337 and retaining nut. Note: If Stall Nut is not used, piston
Fill Bottle must be pushed to the full forward position before
2. Fill bleed bottle almost full Assembly installing valves.
of DEXRON III - ATF or
equivalent. (Fig.6) Step 4
Attach the tool air source momentarily to seat air piston
WARNING: Avoid contact with hydraulic at bottom of cylinder. Disconnect tool. With fill port
fluid. Hydraulic fluid must be disposed of facing up, (check valve on side) lay tool on its side.
in accordance with Federal, State and
Local Regulations. Please see MSDS for Step 5
Hydraulic fluid shipped with tool. Install fill bottle in head fill port (check valve hole).
(Fig. 7 & 8)
Refill tool only when red line on plunger drops below
the red line on the reservoir housing or when tool is Step 6
rebuilt. USE: AUTOMATIC TRANSMISSION FLUID Connect tool to shop air regulated to 20 to 40 psi.
DEXRON III, OR EQUIVALENT. Cycle tool 20-30 times. Watch for air bubbles escaping
from the tool into bottle. (You may rock the tool to free
Step 1 trapped air in the tool.) Do not allow the air to re-enter
Screw Fill Tool P/N 112465 into Reservoir Plunger, pull the tool.
Plunger into Housing and lock Fill Tool in full forward WARNING: Air pressure MUST be set to 20
position by tilting handle (long side touching tool) and to 40 psi to prevent possible injury from
locking in place. (Fig. 7) high pressure spray. If plug (71) is
removed, fill bottle must be in place before
Stall Nut 8
FIG. 7
cycling tool.
120824
Step 7
When air bubbles no longer appear in bottle, remove fill
bottle while tool is lying on its side.
HUCK 255
Fill Tool FIG. 8
112465
Red Line 64
Indicator

84 83
83
71 75

85 87 86

76 77 1

12
255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

F ILL AND B LEED ( CONTINUED )

Step 8 Step 10
Install the check valve Ball (77), Guide (76) and Spring Unlock Fill Tool and check Reservoir red line. At this
(75). Replace the Plug (71). (Fig. 7) Note: When point cycle tool with Stall Nut attached (Optional. See
cycling tool, always hold bottle up as shown in Figure 8 note) and retaining nut locked in the full forward
to prevent drawing in air from empty part of bottle. position (“Dead Stall”). Reservoir should not drop below
the red line on the reservoir housing.NOTE: Dead
Step 9 Stalling is not necessary if Optional Stall nut was not
Turn tool so front of head faces you and remove the used; just cycle tool.
relief valve Plug (83). Prior to removing Plug (83), it is
advisable to back out setscrew inside of plug by Step 11
approximately 1/2 turn counterclockwise. (See Figure Re-lock the fill tool in out position. Lay tool on its left
8a). This ensures that the Piston will remain in full- side and remove Bleed Plug (64). Top off reservoir by
forward position. Install relief valve Ball (87), Guide placing a few drops of oil in hole and wait for air bubbles
(86), Sleeve (85) and Spring (84). Replace the Plug to escape. Push a pin or a scribe into hole to check for
(83). trapped air bubbles. Replace plug. (Fig. 7)
WARNING:Failure to re-lock the fill tool
FIG. 8a will result in oil being ejected from the
head under pressure during the topping
off of the reservoir. Severe personal injury
may result.

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
Using a 3/32 Allen plunger does not drop when tool is cycled. NOTE: This
wrench, loosen usually requires 3 to 4 times topping off.
setscrew inside Plug by SECTION A-A
approx. 1/2 turn. from Figure 9
Step 13
Remove fill tool and stall nut (if used). Install a nose
assembly and pull several fasteners to test function.

S TICKER L OCATIONS

Partial view of Cylinder Base for Sticker Placement Clarity

13
255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

A SSEMBLY D RAWING
11 92 15 14 12 13 12 19 16 17 FIG. 9
89 8 18 93 20
91
21

A A

7 6 9 10
23 24
5 22 27 25
34 35 4 26
69
(4) 3
27 RETURN Gland Assembly
33 2 90

1 28 24
66 32 25
65 29
31 30
68 67 64 Piston
Assembly 94 PULL Gland Assembly

63
54 36
See Detail 37
Below

53
38
52

51
95 41
50
49
39
48
47 40

46
45 44 43 42 45 64 65
80 79
81
58 82(2)
59 78
60 57
77
56
61 76
62 55
75

74

54 83 73
Gland Assembly
SECTION A-A 88 72 72 25
25 72 84 85 86 87 25 25 64 65 70 71 65
14
255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

P ARTS L IST
ITEM DESCRIPTION Part No. QTY ITEM DESCRIPTION Part No. QTY
1 Handle & Sleeve Assembly 125641 1 53** Cylinder Assembly 115556 1
2 Cable 125643 1 54 Gland Assembly 116173 1
3 Throttle Lever 124333-2 1 55 O-Ring 500786 1
4 Trigger Pin 505496 1 56 QUAD Ring 501074 1
5 Roll Pin 500621 1 57 Back-up Ring 501090 1
6 Pintail Tube 126087 1 58 O-Ring 500784 1
7 Stop 110670 1 59 Retaining Ring 505939 1
8 Retaining Nut 117824 1 60 Spacer 123904 1
9 Wiper Seal 505894 61 Polyseal 506611 1
1
10 Polyseal 506160 62 Gland 123903 1
1
11 Piston 126083 63 Screw 502482 2
1
64 Bleed Plug 100309 3
12 Back-up Ring 113251 2
65 O-ring 505438 4
13 O-ring 500851 1
66 Throttle Arm 127690 1
14 O-ring 500823 1
67 Screw & Bushing Assembly 127029 1
15 Back-up Ring 126088 1 68 Guard 125656 1
16 O-ring 505887 1 69 Cap Screw 500102 4
17 Back-up Ring 113253 1 70 Plug 120204 1
18 Polyseal 129944 1 71 Plug 111068 1
19 HUCK and Yr of Mfr Sticker 590517 1 72 O-ring 505446 3
20 End Cap 112491 1 73 Pin 120203 1
21 Pintail Deflector 124211 1 74 Screw 120129 1
22 Return Gland Assembly 112502 1 75 Spring 100874 1
23 Return Gland 112427 1 76 Guide 111067 1
24 O-Ring 500776 2 77 Ball 502929 1
25 Back-up Ring 501082 6 78 Seat 111139 1
26 O-Ring 500778 1 79 Reservoir Plunger 112405 1
27 Back-up Ring 501084 3 80 QUAD Ring 501408 1
28 Gland 112426 1 81 Housing/Spacer Assembly 112403 1
29 Back-up Ring 501087 1 82 Spring 505864 2
30 O-Ring 500781 1 83 Plug 114530 1
31 Hydraulic Piston Assembly 118865 1 84 Spring 505863 1
32 Screw 117773 1 85 Sleeve 120127 1
33 O-Ring 503768 1 86 Valve Guide 120128 1
34 Piston 117774 87 Ball 502506 1
1
35 O-Ring 500773 88 Seat 114528 1
1
Throttle Valve Assy (contains 89 Head Assembly 126079 1
36 Throttle Valve - not sold separately, 115558 1 90 Pull Gland Assembly 112501 1
and Items 37, 39, and 40) 91 Wiper Housing 123138 1
37 O-Ring 504408 2 92 Front Gland 126081 1
38 Air Hose Assembly 115436 1 93 Rear Gland 126085 1
39 O-Ring 504407 1 94 Set Screw 502053 1
40 Spring 116272 1 95 Silicone Cover 129710 1
41 Self-Locking Nut 121241 1 96** Max Pressure & Flow Sticker 590350 1
42 Muffler End Cap 116585 1 97** CE Sticker 590351 1
43 Muffler 115554 1 98** HUCK Address Sticker 590347 1
44 O-Ring 500777 1
45 Screw, Button Head 504127 ** The 255 series tools come labeled with important
3
46 Gasket 126941-2 1 stickers which contain safety information. It is
47 Retaining Ring 505025 1 necessary that these stickers remain on the tool and
48 O-Ring 500873 1 are easily read. If any sticker becomes damaged or
49 Cylinder Head 111959 1 worn, or when replacing a cylinder, the stickers must
50 QUAD Ring 501460 1 be ordered and placed in the locations shown on
51 Air Piston 100315 1 page 13 of this manual.
52 Piston Rod 112414 1
15
 255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

T ROUBLESHOOTING

Always check out the simplest possible cause of a 5 Hydraulic fluid exhausts with air or leaks at base of
malfunction first. For example, an air hose not handle.
connected. Then proceed logically, eliminating each
possible cause until the cause is located. Where a) Worn or damaged Gland Assembly (54)
possible, substitute known good parts for suspected bad inspect Polyseal (61), O-rings (58 and 55),
parts. Use TROUBLESHOOTING CHART as an aid in Quad-ring (56) and Back-up ring (57) replace if
locating and correcting malfunction. necessary.

NOTE: 6. Hydraulic fluid leaks at rear of Pull Piston (11)

“Piston drift” is when the air piston is in the down a) Worn or damaged Rear Gland (93): Inspect
position, but the hydraulic pull piston is not in the full O-rings (16 and 18) and Back-up Rings (17
follward position. This causes an out of sequence and 19). Replace if necessary.
condition.
7. Hydraulic fluid leaks at front of Pull Piston (11).
1 Tool fails to operate when trigger is depressed.
a) Worn or damaged Front Gland (92): Inspect
a) Air line not connected
Polyseal (10), O-ring (14) and Back-up Ring (15).
b) Throttle Valve O-rings (37 & 39), worn or Replace if necessary.
damaged.
c) Throttle Valve Cable (2) is broken. 8. Pull Piston (11) will not return.

2 Tool does not complete fastener installation and a) Throttle Valve (36) stuck: Lubricate O-rings
break pintail. (37 & 39).
b) Throttle Arm (66), Cable (2) or Trigger (3)
a) Air pressure too low binding.
b) Air Piston Quad-ring (50) worn or damaged.
c) Reservoir empty or low, refer to Fill and Bleed 9. Air leaks at air Cylinder Head (49).
section.
d) Air in hydraulic system, refer to Fill and Bleed a). Worn or damaged O-ring (48). Replace if
section. necessary.
e) Reservoir Springs (82) worn or damaged
f) Check for piston drift

3 Pintail stripped and/or swaged collar not ejected.

A CCESSORIES
a) Check for broken or worn jaws in nose Service Kit - 255KIT
assembly, refer to nose assembly data sheet. (includes most consumable parts such as seals,
b) Check for loose Retaining Nut (8) deflector, springs, etc.)
c) Check for piston drift.
Stall Nut (Fig. 7) - 120824
4 Tool has piston drift.
Service Tool Kit - 126104
a) Loose collet crashing into the front of the anvil, Includes:
this causes the relief valve to open allowing the Assembly Bullet (Fig.2) - 123111-1
piston to drift. Tighten the collet and refer to Fill Spacer (Fig. 2) - 123112-1
and Bleed section.
b) Worn or damaged Return Pressure Relief Valve
in tool, inspect Seat (88), O-ring (72), Back-up
Rings (25), Steel Ball (87) and Valve Spring (84).
Replace if necessary.
c) Worn or damaged Piston Assembly (31); inspect
O-ring (33), O-ring (35) and Back-up rings (27).
Replace if necessary.

16
255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

L IMITED WARRANTIES
TOOLING WARRANTY: TO THE TOOLING, PART(S) OR OTHER ITEMS
Huck warrants that tooling and other items (excluding MANUFACTURED BY THIRD PARTIES. HUCK
fasteners, and hereinafter referred as "other items") EXPRESSLY DISCLAIMS ANY WARRANTY
manufactured by Huck shall be free from defects in EXPRESSED OR IMPLIED, AS TO THE
workmanship and materials for a period of ninety (90) CONDITION, DESIGN, OPERATION,
days from the date of original purchase. MERCHANTABILITY OR FITNESS FOR USE OF
ANY TOOL, PART(S), OR OTHER ITEMS THEREOF
WARRANTY ON "NON STANDARD OR CUSTOM NOT MANUFACTURED BY HUCK. HUCK SHALL
MANUFACTURED PRODUCTS": NOT BE LIABLE FOR ANY LOSS OR DAMAGE,
With regard to non-standard products or custom DIRECTLY OR INDIRECTLY, ARISING FROM THE
manufactured products to customer's specifications, USE OF SUCH TOOLING, PART(S) OR OTHER
Huck warrants for a period of ninety (90) days from ITEMS OR BREACH OF WARRANTY OR FOR ANY
the date of purchase that such products shall meet CLAIM FOR INCIDENTAL OR CONSEQUENTIAL
Buyer's specifications, be free of defects in DAMAGES.
workmanship and materials. Such warranty shall not The only warranties made with respect to such tool,
be effective with respect to non-standard or custom part(s) or other items thereof are those made by the
products manufactured using buyer-supplied molds, manufacturer thereof and Huck agrees to cooperate
material, tooling and fixtures that are not in good with Buyer in enforcing such warranties when such
condition or repair and suitable for their intended action is necessary.
purpose.
Huck shall not be liable for any loss or damage
THERE ARE NO WARRANTIES WHICH EXTEND resulting from delays or nonfulfillment of orders owing
BEYOND THE DESCRIPTION ON THE FACE to strikes, fires, accidents, transportation companies
HEREOF. HUCK MAKES NO OTHER or for any reason or reasons beyond the control of the
WARRANTIES AND EXPRESSLY DISCLAIMS ANY Huck or its suppliers.
OTHER WARRANTIES, INCLUDING IMPLIED
WARRANTIES AS TO MERCHANTABILITY OR AS HUCK INSTALLATION EQUIPMENT:
TO THE FITNESS OF THE TOOLING, OTHER Huck International, Inc. reserves the right to make
ITEMS, NONSTANDARD OR CUSTOM changes in specifications and design and to
MANUFACTURED PRODUCTS FOR ANY discontinue models without notice.
PARTICULAR PURPOSE AND HUCK SHALL NOT
BE LIABLE FOR ANY LOSS OR DAMAGE, Huck Installation Equipment should be serviced by
DIRECTLY OR INDIRECTLY, ARISING FROM THE trained service technicians only.
USE OF SUCH TOOLING, OTHER ITEMS,
NONSTANDARD OR CUSTOM MANUFACTURED Always give the Serial Number of the equipment
PRODUCTS OR BREACH OF WARRANTY OR FOR when corresponding or ordering service parts.
ANY CLAIM FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES. Complete repair facilities are maintained by Huck
International, Inc. Please contact one of the offices
Huck's sole liability and Buyer's exclusive remedy for listed below.
any breach of warranty shall be limited, at Huck's
option, to replacement or repair, at FOB Huck's plant, Eastern
of Huck manufactured tooling, other items, One Corporate Drive Kingston, New York 12401-0250
nonstandard or custom products found to be defective Telephone (845) 331-7300 FAX (845) 334-7333
in specifications, workmanship and materials not Outside USA and Canada
otherwise the direct or indirect cause of Buyer Contact your nearest Huck International Office, see
supplied molds, material, tooling or fixtures. Buyer back cover.
shall give Huck written notice of claims for defects
within the ninety (90) day warranty period for tooling, In addition to the above repair facilities, there are
other items, nonstandard or custom products Authorized Tool Service Centers (ATSC's) located
described above and Huck shall inspect products for throughout the United States. These service centers
which such claim is made. offer repair services, spare parts, Service Parts Kits,
Service Tools Kits and Nose Assemblies. Please
TOOLING, PART(S) AND OTHER ITEMS NOT contact your Huck Representative or the nearest
MANUFACTURED BY HUCK: Huck office listed on the back cover for the ATSC in
HUCK MAKES NO WARRANTY WITH RESPECT your area.
17
 255 SERIES PNEUDRAULIC TOOLING (HK1014) Alcoa Fastening Systems

For the Long Haul™

A Global Organization
Alcoa Fastening Systems (AFS) maintains company industrial and Aerospace centers, where they
offices throughout the United States and Canada, provide a ready source of AFS fasteners, installation
with subsidiary offices in many other countries. tools, tool parts, and application assistance.
Authorized AFS distributors are also located in
many of the world’s

Alcoa Fastening Systems world-wide locations:

Americas Far East Europe

Alcoa Fastening Systems Alcoa Fastening Systems Alcoa Fastening Systems Alcoa Fastening Systems
Aerospace Products Industrial Products Industrial Products Industrial Products
Tucson Operations Kingston Operations Australia Operations United Kingdom Operations
3724 East Columbia 1 Corporate Drive 14 Viewtech Place Unit C, Stafford Park 7
Tucson, AZ 85714 Kingston, NY 12401 Rowville, Victoria Telford, Shropshire
800‐234‐4825 800‐278‐4825 Australia 3178 England TF3 3BQ
520‐747‐9898 845‐331‐7300 03‐764‐5500 01952‐290011
FAX: 520‐748‐2142 FAX: 845‐334‐7333 Toll Free: 008‐335‐030 FAX: 0952‐290459
FAX: 03‐764‐5510
Alcoa Fastening Systems
Alcoa Fastening Systems Alcoa Fastening Systems Aerospace Products
Aerospace Products Industrial Products France Operations
Carson Operations Latin America Operations Clos D’Asseville
PO Box 5268 Avenida Parque Lira. 79‐402 BP4
900 Watson Center Rd. Tacubaya Mexico, D.F. 95450 Us Par Vigny
Carson, CA 90749 C.P. 11850 France
800‐421‐1459 FAX: 525‐515‐1776 33‐1‐30‐27‐9500
310‐830‐8200 TELEX: 1173530 LUKSME FAX: 33‐1‐34‐66‐0600
FAX: 310‐830‐1436

Alcoa Fastening Systems Certified to

ISO 9001:2008
Industrial Products
Industrial
Waco Operations Products
PO Box 8117 Industrial
8001 Imperial Drive Products
Certified to
Waco, TX 76714‐8117 ISO 14001:2004
800‐388‐4825
254‐776‐2000
FAX: 254‐751‐5259

For The Long Haul, The Future of Fastening and/or the means for selecting such products,
Technology, The Future of Assembly Technology, and is not intended to create any warranty,
The Future of Tooling Technology, and Tools of express, implied, or statutory; all warranties are
Productivity are service marks of Huck contained only in Huck’s written quotations,
International. Huck provides technical assistance acknowledgements, and/or purchase orders. It is
regarding the use and application of Huck recommended that the user secure specific, up‐
fasteners and tooling. to‐date data and information regarding each
NOTICE: The information contained in this application and/or use of such products.
publication is only for general guidance with HWB898 1003‐5M
regard to properties of the products shown One Great ConnectionSM

© 2003 Alcoa Fastening Systems

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