256BT Pneudraulic Installation Tool
(HK1109)
Alcoa Fastening Systems
10
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 256BTKIT
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, Place Cylinder
(28) on handle with Timing Pin positioned in
matching hole. Assemble Gland Assembly (29)
and screw it into handle. (Fig. 9) Torque to 100 -
120 ft. lbs. using 1 3/8 socket wrench.
2. Push Air Piston/Rod assembly with Quad Ring
(26b) in place into air cylinder until it reaches top of
cylinder. (Fig. 3)
3. Turn tool upright. Install Hydraulic Piston
Assembly (30)
(with O-ring (30c) and Back-up
Rings (30d) in place)
in handle. Press in from top
of handle taking care not to damage seals. (Fig. 4)
4. Push Screw (30b) with O-ring (30e) in place
through Hydraulic Piston (30a) and screw into top
of piston rod. Hold Nut (19) with 9/16 socket and
extension and torque Screw (30b) using 7/64 hex
key to 55 - 60 in. lbs.
5. Hold handle in vise with bottom facing up. Push
Cylinder Head (25a) with O-ring (25b) in place
squarely into cylinder. Install Retaining Ring (24).
(Fig. 3 & 9)
6. Position O-ring (22) and Muffler (21) on center of
Cylinder Assy (25). Place Gasket (23) on Cylinder
Assembly (28).
NOTE:
Lip must face Muffler End
Cap (20).
Place Muffler End Cap (20) on top of
Gasket (23), and secure with 3 Button Head
Screws (18) using 1/8 hex key. (Fig. 3)
7. Turn tool upright. Drop Spring (17d) into Throttle
Valve hole in cylinder. Push Throttle Valve (17a)
with O-rings (17b & 17c) in place into cylinder. (Fig.
9)
8. Assemble Trigger (3) Cable (2) and Trigger Pin (4),
and slide cable into Handle (1). Align hole in
trigger with hole in handle and install Roll Pin (5)
with a hammer and punch. (Fig. 9)
9. Slide Throttle Arm (36) onto ball end of throttle
cable. Swing arm until other end fits over throttle
valve. Push Screw (35) through Throttle Arm (36).
Tighten with 5/32 hex key.
10. If Air Hose Assembly (38) was removed, reinstall in
Cylinder Assembly (28).
11.
{If Seat Assy (52) is being replaced}:
Push Plug
(51)
(with O-ring 48 & Back-up Ring 47 in place)
into head. Install Screw (46). (Fig. 9)
12. Install O-ring (52c) and Back-up Rings (52b ) onto
Seat (52a). Drive Seat Assy (52) in using soft drift
taking care not to damage Relief Valve Ball (53)
surface. (Fig. 9, Section A-A)
13. Assemble Pull Piston (11a) with new Seals (11b &
11c). Lubricate with LUBRIPLATE or PARKER
SUPER-O-LUBE and install. (Fig. 9 & 10)
14. Push Front Gland Assy (10) with all seals, housing
and wiper in place (Figure 2) over Assembly Bullet
and onto Pull Piston Assy (11). (Fig. 9 & 10)
A
A
SSEMBLY
SSEMBLY
CAUTION: Do NOT scratch piston rod.
WARNING: Do not omit any seals during
servicing, leaks will result and personal
injury may occur.
WARNING: Tool must be fully assembled
with all components included.
19
30
Piston
Assembly
FIG. 4