11
244/244OS Series Tooling Alcoa Fastening Systems
(See Figures 4 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 Back-up rings in Service Parts
Kit, P/N 244KIT. 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
Assembly (33) (with O-ring (35) and Back-up rings
(36) in place) in handle. (Fig. 4)
2. Place Cylinder Assembly (51) on handle with Timing
Pin (50) positioned in matching hole. Assemble
Gland Assembly (41) (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 (63) through Air Piston (61) from
flat side. Drop Washer (59) over thread and screw
Locknut (58) onto rod. Hold hex of rod with 9/16
wrench, and torque nut using 9/16 socket to 28-32 ft.
lbs. (Fig 5). CAUTION:Do not scratch piston rod.
4. Push assembled Air Piston and Rod into Air Cylinder
and Gland Assembly (41) until it stops. Push Screw
(34) with o-ring in place through hydraulic Piston
Assembly (33) and screw into top of piston rod. Hold
Locknut (58) with 9/16 socket and extension and
torque Screw (34) using 7/64 hex key to 55-60 in.
lbs.
5. Push Cylinder Head (60) with O-ring (53) in place
squarely into Cylinder. Install Retaining Ring (62).
(Fig. 6)
6. Hold handle upside down in vise. Position Muffler
(57) on center of Cylinder Head (60), Place Gasket
(54) on Cylinder Assembly (51), place Bottom Plate
(56) on top of Gasket and secure with 3 Button Head
Screws (55) using 1/8 hex key. (Fig. 6)
7. Turn tool upright. Drop Spring (65) into Throttle
Valve hole in Cylinder. Push Throttle Valve (67) with
O-rings (66) in place into Cylinder. (Fig. 6)
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. 6)
9. Slide Throttle Arm (68) onto ball end of Throttle
Cable. Swing arm until other end fits over throttle
valve.Place Lever Guard (94) over Throttle Arm and
install Pivot Screw (64) through Throttle Arm. Tighten
with 5/32 hex key.
10. Install Swivel Assembly (86) in Cylinder Assembly
(51). (Fig. 9)
11. If Air Hose 115436 was removed, reinstall in swivel
assembly.
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