256 Pneudraulic Installation Tool (HK1015)
9
Equipment Required:
- Shop airline 90-100 psi max.
- Air regulator
- Fill Bottle (Fig. 7, supplied with
tool)
- Fill Tool 112465
- Large flat blade screwdriver
- Stall Nut 120824
- Nose assembly
- Fasteners (Optional)
Preparation:
1. Install air regulator in airline,
and set pressure to 20-40 psi.
2. Fill bottle almost full of DEXRON III - ATF (automatic
transmission fluid).
NOTE: Refill tool only when red line on
plunger drops below the red line on the reservoir housing
or when tool is rebuilt.
FOR PARTS IDENTIFICATION, SEE FIGURES 10 AND 11.
STEP 1:
Screw Fill Tool into Reservoir Plunger, pull Plunger into
Reservoir Housing and lock Fill Tool in full forward position by
tilting handle (long side touching tool) and locking in place.
(Figure 8)
STEP 2:
Remove Relief and Check Valve Plugs, Guides, Springs
and Balls from ports in head. Reinstall Plug and Sleeve in head in
Relief Valve port (front of tool).
STEP 3:
Screw retaining nut onto Head Assembly. Screw Stall
Nut onto Hydraulic Piston and tighten to ensure full thread
engagement. Back off Retaining Nut until it engages Stall Nut.
Check that Hydraulic Piston is all the way forward and locked with
Retaining Nut and with (or without) Stall Nut.
STEP 4:
Attach the tool air source momentarily to seat Air Piston
at bottom of Air Cylinder, then disconnect tool.
With Reservoir
Fill port facing up, lay tool on
its side.
STEP 5:
Install Fill Bottle in
Reservoir Fill port. (Figure 9)
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
10 to prevent drawing in air from empty part of bottle.
STEP 7:
When air bubbles no longer appear in bottle, remove Fill
Bottle and replace the Reservoir Fill Plug
while tool is lying on
its side.
STEP 8:
Install the Check Valve Ball, Guide and Spring. Replace
the Check Valve Plug.
STEP 9:
Turn tool so front of head faces you. Prior to removing
Relief Valve Plug, using a 3/32 Allen wrench, back out setscrew
inside of the plug approximately 1/2 turn counterclockwise.
This ensures that the Piston will remain in full-forward position.
Remove the Relief Valve Plug, install Ball, Guide, Sleeve and
Spring, and replace the plug.
STEP 10:
Unlock Fill Tool and check Reservoir red line. 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 side and remove
Reservoir Fill Plug. 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.
STEP 12:
Unlock the Fill Tool and cycle tool as in step 10.
Reservoir may drop slightly. If so, repeat step 11 until, when the
Fill Tool handle is touched, it has no pressure against it and it
drops out of the lock position, and the Reservoir 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.
WARNING: Avoid contact with hydraulic fluid.
Hydraulic fluid must be disposed of in accordance
with Federal, State and Local Regulations.
120337 Fill Bottle Assy
120336
Fill Bottle
120004 Cap
Fill Point
Figure 7
WARNING: Air pressure MUST be set to 20 to 40 psi
to prevent possible injury from high pressure spray.
If Check Valve Plug is removed, Fill Bottle must be in
place before cycling tool.
(Check Valve port)
Install Fill Bottle here
Reservoir
Fill Plug
Check Valve Plug
Relief
Valve
Plug
Red line indicator
120824 Stall Nut
112465 Fill Tool
(Shown in LOCK
position.)
Retaining Nut
Reservoir
Housing
Figure 8
Fill Bottle
shown in
Reservoir
Fill Port
Figure 9
Fill and Bleed
WARNING: Failure to re-lock 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.
