256 Pneudraulic Installation Tool (HK1015)
Alcoa Fastening Systems & Rings
11
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.
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.
Figure 8
Figure 9
F i l l a n d B l e e d
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.
