10
254 and 254OS Pneudraulic Installation Tools (HK1172)
Clean components with mineral spirits or similar solvent.
Inspect for wear/damage and replace as necessary.
Replace all seals of disassembled components using
Service Parts Kit, P/N 256KIT. Smear LUBRIPLATE 130AA
or PARKER-O-LUBE on rings and mating parts to ease
assembly. Carefully assemble tool without damaging
O-rings, Quad rings, or Back-up rings.
1. (Figure 4) Install O-ring inside handle; then push sleeve
in handle until it bottoms on the chamfer.
2. Holding handle inverted in a vice, install timing pin; then
place air cylinder on handle with timing pin positioned
in matching hole. Assemble Main Gland Assembly. Apply
anti-seize compound (p/n 508183) to gland threads.
With a 1-3/8 inch socket wrench, torque it into the
handle to 75-85 foot lbs.
3. Push air piston assembly and piston rod into air cylinder
until it seated inside of air cylinder (See Figure 3).
4. Turn tool upright. Assemble Intensifier Piston with
O-Ring and Back-up Rings; then apply Loctite 243 to
intensifier piston screw threads, and carefully press in
from top of handle.
5. Holding Self-locking Nut with 9/16 socket and extension,
screw intensifier piston onto piston rod using 7/64 hex
key, and torque to 180-190 in. lbs.
6. Hold handle in vise with bottom up. Push Cylinder Head
Assembly squarely into air cylinder. Install Retaining Ring.
7. Position O-Ring and Muffler on center of air cylinder.
Place Bottom Exhaust Gasket on air cylinder. Place
Muffler End Cap on top of Gasket, and secure with 3 Cap
Screws using 5/32 hex key.
8. Turn tool upright. (Figure 5) Drop Throttle Valve Spring
into Throttle Valve hole in cylinder. Push Throttle Valve,
with O-rings in place, into cylinder.
9. Assemble Trigger, Cable, and Cable Pin, and slide Cable
into Handle. Align hole in Trigger with hole in Handle
and install Trigger Pin with a hammer and punch.
10. Slide Throttle Arm onto ball end of throttle cable. Swing
arm until end fits over throttle valve. Attach throttle arm
Bushing and Screw to Throttle Arm. Tighten with 5/32
hex key.
11. If air hose assembly was removed, reinstall it.
12. If replacing Relief Valve Seat Assy, push Plug “A”, with
seals in place, into head. Install Screw “B”. (Figure 10)
13. Carefully drive Relief Valve Seat Assy in using a soft
drift, without damaging Relief Valve Ball surface.
14. Assemble Pull Piston with new seals. Lubricate with
LUBRIPLATE or PARKER SUPER-O-LUBE.
15. Thread Assembly Bullet onto Pull Piston Assy. (Figure 2)
NOTE:
Spacer not needed during assembly. Its purpose
is to push out the front gland during disassembly.
16. Push Front Gland Assy, with seals, Housing, and Wiper
in place, over Assembly Bullet and onto Pull Piston.
Push entire gland and piston assembly into Head.
17. (Figure 10) Install O-rings and Back-up Rings on Rear
Gland and push complete assembly into Head. Screw in
Cylinder Cap and tighten.
18. (Figure 10) Install O-ring & Back-up Ring on Relief
Valve Plug; then install Ball, Guide, Sleeve, Spring, and
assembled Relief Valve Plug into head.
19. Install O-ring on Check Valve Plug “D”, then install Ball,
Guide, Spring, and assembled Check Valve Plug into
head.
20. Push Pintail Deflector onto barbed end of Pull Piston
(254 only).
21. (Figure 10) Place O-rings on Bleed Plugs “C” & “E” and
screw assemblies into Handle and Cylinder Head.
22. (Figure 10) Install all O-rings and Back-up Rings on Pull
and Return Glands. Push Gland Assemblies into handle.
Push Head down on glands.
23. Place tool in a vise, head down, and install 4 Cap
Screws, and proceed to Fill & Bleed section of this
manual.
Assembly
Handle shown
partially
transparent
for clarity.
Chamfers of
sleeve and
handle meet
here
O-ring inside
groove in handle
Sleeve pushed
in from top of
handle
Figure 4
Trigger Pin
Cable Pin
Cable Assembly
Throttle Arm
Guard Screw
(not shown)
Throttle Arm
Spring
Throttle Valve
with
3
O-rings
in place
Setscrew
Throttle Arm Guard
Throttle Arm
Bushing and Screw
Figure 5
