Applifast 255 User manual

(Shown without silicone boot.)
Instruction Manual
Alcoa Fastening Systems
Model 255
Pneudraulic Rivet Tool

255 SERIES PNEUDRAULIC TOOLING (HK1014)
2

255 SERIES PNEUDRAULIC TOOLING (HK1014)
3
C
CONTENTS ONTENTS
EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
FILL AND BLEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

255 SERIES PNEUDRAULIC TOOLING (HK1014)
4
I. GENERAL SAFETY RULES:
1. A half hour long hands-on training session with qualified personnel is
recommended before using Huck equipment.
2. Huck equipment must be maintained in a safe working condition at all
times. Tools and hoses should be inspected at the beginning of each
shift/day for damage or wear. Any repair should be done by a qualified
repairman trained on Huck procedures.
3. For multiple hazards, read and understand the safety instructions before
installing, operating, repairing, maintaining, changing accessories on, or
working near the assembly power tool. Failure to do so can result in
serious bodily injury.
4. Only qualified and trained operators should install, adjust or use the
assembly power tool.
5. Do not modify this assembly power tool. This can reduce effectiveness of
safety measures and increase operator risk.
6. Do not discard safety instructions; give them to the operator.
7. Do not use assembly power tool if it has been damaged.
8. Tools shall be inspected periodically to verify all ratings and markings
required, and listed in the manual, are legibly marked on the tool. The
employer/operator shall contact the manufacturer to obtain replacement
marking labels when necessary. Refer to assembly drawing and parts list
for replacement.
9. Tool is only to be used as stated in this manual. Any other use is
prohibited.
10. Read MSDS Specifications before servicing the tool. MSDS
specifications are available from the product manufacturer or your Huck
representative.
11.Only genuine Huck parts shall be used for replacements or spares. Use
of any other parts can result in tooling damage or personal injury.
12.Never remove any safety guards or pintail deflectors.
13.Never install a fastener in free air. Personal injury from fastener ejecting
may occur.
14.Where applicable, always clear spent pintail out of nose assembly before
installing the next fastener.
15.Check clearance between trigger and work piece to ensure there is no
pinch point when tool is activated. Remote triggers are available for
hydraulic tooling if pinch point is unavoidable.
16.Do not abuse tool by dropping or using it as a hammer. Never use
hydraulic or air lines as a handle or to bend or pry the tool. Reasonable
care of installation tools by operators is an important factor in maintaining
tool efficiency, eliminating downtime, and preventing an accident which
may cause severe personal injury.
17.Never place hands between nose assembly and work piece. Keep hands
clear from front of tool.
18.Tools with ejector rods should never be cycled with out nose assembly
installed.
19.When two piece lock bolts are being used always make sure the collar
orientation is correct. See fastener data sheet for correct positioning.
II. PROJECTILE HAZARDS:
1. Risk of whipping compressed air hose if tool is pneudraulic or pneumatic.
2. Disconnect the assembly power tool from energy source when changing
inserted tools or accessories.
3. Be aware that failure of the workpiece, accessories, or the inserted tool
itself can generate high velocity projectiles.
4. Always wear impact resistant eye protection during tool operation. The
grade of protection required should be assessed for each use.
5. The risk of others should also be assessed at this time.
6. Ensure that the workpiece is securely fixed.
7. Check that the means of protection from ejection of fastener or pintail is in
place and operative.
8. There is possibility of forcible ejection of pintails or spent mandrels from
front of tool.
III. OPERATING HAZARDS:
1. Use of tool can expose the operator’s hands to hazards including:
crushing, impacts, cuts, abrasions and heat. Wear suitable gloves to
protect hands.
2. Operators and maintenance personnel shall be physically able to handle
the bulk, weight and power of the tool.
3. Hold the tool correctly and be ready to counteract normal or sudden
movements with both hands available.
4. Maintain a balanced body position and secure footing.
5. Release trigger or stop start device in case of interruption of energy
supply.
6. Use only fluids and lubricants recommended by the manufacturer.
7. Avoid unsuitable postures, as it is likely for these not to allow
counteracting of normal or unexpected tool movement.
8. If the assembly power tool is fixed to a suspension device, make sure that
fixation is secure.
9. Beware of the risk of crushing or pinching if nose equipment is not fitted.
IV. REPETITIVE MOTION HAZARDS:
1. When using assembly power tool, the operator can experience discomfort
in the hands, arms, shoulders, neck or other parts of the body.
2. When using tool, the operator should adopt a comfortable posture while
maintaining a secure footing and avoid awkward or off balanced postures.
3. The operator should change posture during extended tasks to help avoid
discomfort and fatigue.
4. If the operator experiences symptoms such as persistent or recurring
discomfort, pain, throbbing, aching, tingling, numbness, burning
sensations or stiffness, these warnings should not be ignored. The
operator should tell the employer and consult a qualified health
professional.
V. ACCESSORIES HAZARDS:
1. Disconnect tool from energy supply before changing inserted tool or
accessory.
2. Use only sizes and types of accessories and consumables that are
recommended. Do not use other types or sizes of accessories or
consumables.
VI. WORKPLACE HAZARDS:
1. Be aware of slippery surfaces caused by use of the tool and of trip
hazards caused by the air line or hydraulic hose.
2. Proceed with caution while in unfamiliar surroundings; there could be
hidden hazards such as electricity or other utility lines.
3. The assembly power tool is not intended for use in potentially explosive
environments.
4. Tool is not insulated against contact with electrical power.
5. Ensure there are no electrical cables, gas pipes, etc., which can cause a
hazard if damaged by use of the tool.
VII. NOISE HAZARDS:
1. Exposure to high noise levels can cause permanent, disabling hearing
loss and other problems such as tinnitus, therefore risk assessment and
the implementation of proper controls is essential.
2. Appropriate controls to reduce the risk may include actions such as
damping materials to prevent workpiece from ‘ringing’.
3. Use hearing protection in accordance with employer’s instructions and as
required by occupational health and safety regulations.
4. Operate and maintain tool as recommended in the instruction handbook
to prevent an unnecessary increase in the noise level.
5. Select, maintain and replace the consumable / inserted tool as
recommended to prevent an unnecessary increase in noise.
6. If the power tool has a silencer, always ensure that it is in place and in
good working order when the tool is being operated.
VIII. VIBRATION HAZARDS:
1. Exposure to vibration can cause disabling damage to the nerves and
blood supply to the hands and arms.
2. Wear warm clothing when working in cold conditions and keep hands
warm and dry.
3. If numbness, tingling, pain or whitening of the skin in the fingers or hands,
stop using the tool, tell your employer and consult a physician.
4. Support the weight of the tool in a stand, tensioner or balancer in order to
have a lighter grip on the tool.
IX. PNEUMATIC / PNEUDRAULIC TOOL SAFETY INSTRUCTIONS:
1. Air under pressure can cause severe injury.
2. Always shut off air supply, drain hose of air pressure and disconnect tool
from air supply when not in use, before changing accessories or when
making repairs.
3. Never direct air at yourself or anyone else.
4. Whipping hoses can cause severe injury, always check for damaged or
loose hoses and fittings.
5. Cold air should be directed away from hands.
6. Whenever universal twist couplings (claw couplings) are used, lock pins
shall be installed and whipcheck safety cables shall be used to safeguard
against possible hose to hose or hose to tool connection failure.
7. Do not exceed maximum air pressure stated on tool.
8. Never carry an air tool by the hose.
GLOSSARY OF TERMS AND SYMBOLS:
- Product complies with requirements set forth by the
relevant European directives.
-READ MANUAL prior to using this equipment.
-EYE PROTECTION IS REQUIRED while using this
equipment.
-HEARING PROTECTION IS REQUIRED while using this
equipment.
Notes: are reminders of required procedures.
Bold, Italic type and underlining: emphasizes a specific instruction.
S
SAFETY AFETY I INSTRUCTIONS NSTRUCTIONS
CAUTIONS: show conditions that will
damage equipment and or structure.
WARNINGS: Must be understood to avoid
severe personal injury.

POWER SOURCE:
90‐100psi shop air
HYDRAULIC FLUID:
ATF meeting DEXRON III, DEXRON IV, MERCON, Allison C‐4 or equivalent specifications.
Fire resistant hydraulic fluid may also be used, and is required to comply with OSHA regulation
1926.302 paragraph (d): "the fluid used in hydraulic power tools shall be fire resistant fluid approved
under schedule 30 of the US Bureau of Mines, Department of Interior, and shall retain its operating
characteristics at the most extreme temperatures to which it will be exposed."
MAX OPERATING TEMP:
125°F (51.7°C)
MAX FLOW RATE:
11.5 scfm (325.64 l/m)
MAX AIR PRESSURE:
100 psi (6.9 bar)
MIN PULL CAPACITY:
7500 lbs (34.47 kN) @ 90 psi
MIN STROKE:
.625 inches (1.59 cm)
SPEED/CYCLES:
30 per minute
WEIGHT:
8.8 lbs (3.99 kg)
S
SPECIFICATIONS PECIFICATIONS
255 SERIES PNEUDRAULIC TOOLING (HK1014)
5
HUCK 255
7.091
180.11
14.86
377.59
.959
24.36
1.920
48.77
ø
6.020
153.00
4.610
118.00
ø
3.957
100.51
4°
inches
mm

255 SERIES PNEUDRAULIC TOOLING (HK1014)
6
EXHAUST
HYDRAULIC
PISTON
AIR PISTON
RELIEF
VALVE CHECK
VALVE
PULL PISTON
THROTTLE
VALVE
RESERVOIR
When the trigger is depressed, the throttle valve
moves to down position, and pressurized air is
directed to the bottom of the air piston, causing the
piston to move upward. The air above the piston is
exhausted and directed through the center of the
throttle valve and out the bottom of the tool. The
air piston has a rod and a hydraulic piston attached.
When the air piston rod moves upward, a column of
pressurized fluid is forced into the head, which
moves the pull piston back. The attached nose
assembly moves with the pull piston to start fastener
installation.
When fastener installation is completed, the trigger
is released. Air pressure, with the assistance of a
spring, causes the throttle valve to return to its up
position. Pressurized air is re‐directed to the top of
the air piston, causing the piston to move
downward. The air from below the piston is
exhausted through bottom of tool. The rod and
hydraulic piston move downward, hydraulic pressure
is reversed and the pull piston is returned forward.
The return pressure relief valve protects the tool
against pressure spikes. The reservoir replenishes
the hydraulic system as needed.
PULL RETURN
P
PRINCIPLE RINCIPLE OF OF O OPERATION PERATION

255 SERIES PNEUDRAULIC TOOLING (HK1014)
7
The Model 255 Installation Tool is shipped with a plastic
plug in the air inlet connector. The connector has 1/4-
18 female pipe threads to accept the air hose fitting.
Quick disconnect fittings and 1/4” inside diameter air
hose are recommended. An air supply of 90-100 psi
capable of 11.5 CFM must be available. Air supply
should be equipped with a filter-regulator-lubricator unit.
1. Remove plastic shipping plug from Air Inlet
Connector and put in a few drops of Automatic
Transmission Fluid, DEXRON III, or equivalent.
2. Screw quick disconnect fitting into Air Inlet
Connector.
3. Set air pressure on regulator to 90-100 psi.
4. Attach optional Air Hose (38), supplied with tool, to
air inlet connector.
5. Connect air hose to tool.
6. Cycle tool a few times by depressing and releasing
trigger.
7. Disconnect air hose from tool.
8. Remove Retaining Nut and Stop.
9. Select proper Nose Assembly for fastener to be
installed.
10. Screw Collet Assembly (including lock collar and
shim if applicable) onto Spindle holding Pull Piston
(11) with 3/8 hex key. (Wrench Tight)
11. Slide Anvil over Collet Assembly and into
counterbore.
12. Slide Stop and Retaining Nut over Anvil and screw
Nut onto Head.
13. Connect air hose to tool and install fastener(s) in
test plate of proper thickness with proper size holes.
Inspect fastener(s).
NOTES:
1 Air quick disconnect fittings and air hoses are not
available from Huck International, Inc.
2 Vibra-Tite (Huck P/N 505125) should be used on
collet threads for nose assemblies without lock
collars. All other noses should be staked.
Vibra-Tite is a registered trademark of ND Industries, Inc. USA
GENERAL
1. The efficiency and life of any tool depends upon
proper maintenance. Regular inspection and
correction of minor problems will keep tool operating
efficiently and prevent downtime. The tool should be
serviced by personnel who are thoroughly familiar
with how it operates.
2. A clean, well-lighted area should be available for
servicing the tool. Special care must be taken to
prevent contamination of pneumatic and hydraulic
systems.
3. Proper hand tools, both standard and special, must
be available.
4. All parts must be handled carefully and examined for
damage or wear. Always replace Seals, when tool is
disassembled for any reason. Components should be
disassembled and assembled in a straight line
without bending, cocking, or undue force.
Disassembly and assembly procedures outlined in
this manual should be followed.
5. Service Parts Kit 255KIT includes consumable parts
and should be available at all times. Other components,
as experiece dictates, should also be available.
DAILY
1. If a Filter-Regulator-Lubricator unit is not being used,
uncouple air disconnects and put a few drops of
Automatic Transmission Fluid or light oil into the air
inlet of the tool. If the tool is in continuous use, put a
few drops of oil in every two to three hours.
2. Bleed the air line to clear it of accumulated dirt or
water before connecting air hose to the tool.
3. Check all hoses and couplings for damage or air
leaks, tighten or replace if necessary.
4. Check the tool for damage or air/hydraulic leaks,
tighten or replace if necessary.
5. Check the nose assembly for tightness or damage,
tighten or replace if necessary.
6. Check oil level in tool reservoir, replenish if
necessary.
WEEKLY
1. Disassemble and clean nose assemblies and
reassemble per applicable.
2. Check the tool and all connecting parts for damage or
oil/air leaks, tighten or replace if necessary.
M
MAINTENANCE AINTENANCE
P
PREPARATION REPARATION FOR FOR U USE SE
CAUTION: Do not use TEFLON tape on
threads. Use TEFLON in stick form only:
Huck P/N 503237 TEFLON is a registered
trademark of DuPont Corporation.
WARNING: Inspect tool for damage or
wear before each use. Do not operate if
damaged or worn, as severe personal
injury may occur.

255 SERIES PNEUDRAULIC TOOLING (HK1014)
8
LOCKBOLT® Fastener installation:
Place pin in work hole and place collar over
pin. See WARNING. (If Collar has only one tapered
end, that end must be out toward tool, not next to
sheet.) Hold pin and push nose assembly onto pin
protruding through collar until nose assembly anvil
touches collar. Depress trigger and hold depressed
until collar is swaged and pintail breaks. Release
trigger and tool will go into return stroke. The tool
and nose assembly are ready for the next fastener
installation cycle.
Blind Fastener Installation:
Remove excess gap from between the sheets to
permit correct fastener installation. Fastener may be
placed in work hole or in end of nose assembly.
See WARNING. In either case, tool and nose
assembly must be held against work and at right
angles to it. Depress trigger and hold it depressed
until fastener is installed and pintail breaks. Release
trigger and tool will go into its return stroke. The tool
and nose assembly are ready for next fastener
installation cycle.
Please note
Failure to understand WARNINGS may cause
serious personal injury.
Failure to understand CAUTIONS may cause
damage to structure and Tool.
For additional safety Information, see page 4.
Read all WARNINGS and CAUTIONS prior to using your system.
O
OPERATING
PERATING I
INSTRUCTIONS
NSTRUCTIONS
CAUTION: Remove excess gap from
between the sheets. This permits enough
pintail to emerge from collar for ALL jaw
teeth to engage with pintail. If ALL teeth do
not engage properly, jaws will be
stripped/damaged.
WARNING: Do not pull on a pin without a
collar. The pin will eject with velocity and
force when the pintail breaks off. This may
cause serious injury.
WARNING: Do not pull on a fastener’s pin
without first placing fastener In a work
piece. The fastener will eject forcibly when
the pintail breaks off. This may cause
serious Injury.
CAUTION: To avoid structural and Tool
damage, be sure enough clearance is
allowed for nose assembly at full stroke.
Do not abuse the tool by dropping it, using
it as a hammer or otherwise causing
unnecessary wear and tear. Reasonable
care of installation tools by operators is an
Important factor in maintaining tool
efficiency and reducing downtime.

255 SERIES PNEUDRAULIC TOOLING (HK1014)
9
D
DISASSEMBLY ISASSEMBLY
For component identification and Parts list, refer
to Figures 1 thru 4 and 9.
NOTE: The following procedure is for complete
disassembly of tool. Disassemble only components
necessary to replace damaged O-rings, Quad rings,
Back-up rings, and worn or damaged components.
Always use soft jaw vice to avoid damage to tool.
1. Disconnect air hose from tool.
2. Remove nose assembly. Follow instructions on
Nose Assembly Data sheet.
3. Insert Fill Tool P/N 112465 through reservoir
housing and screw into Reservoir Plunger (79)
locking it in the out position. (Fig. 1)
4. Unscrew Cap Screws (69) with 5/32 hex key.
Carefully lift Head (89) straight up from Handle (1),
remove Pull Gland (90) and Return Gland (22)
from separated assemblies. Remove seals from
glands. (Fig. 1)
5. Unscrew Plug (83) of return Pressure
Relief Valve from front of head. Remove
Spring (84), Valve Guide (86), Sleeve
(85) and Steel Ball (87). A small magnet
is helpful. (Fig. 1)
6. Unscrew Bleed Plug (64). Hold over
waste oil container and release fill tool
slowly. (Fig. 1)
7. Unscrew Reservoir Housing (81) from
head. Remove two Springs (82). Slide
Reservoir Plunger (79) from head.
Remove spacer and Quad Ring (80). A
pick may be used to remove the quad
ring. (Fig. 1)
8. Unscrew Plug (71) of reservoir check
Valve from side of head. Remove Spring
(75), check Valve Guide (76) and
Stainless Steel Ball (77). (Fig. 1)
9. If check Valve Seat (78) is damaged
contact your Huck representative. If Seat
(88) is damaged it can be removed
(through the front of the tool head only)
by using the following procedure.
NOTE: If seat is taken out it can not be reused, it
must be replaced. (Fig. 9)
10. (Seat 88 removal) Note: all parts in the reservoir
check valve must be removed before Plug (70) can
be removed. Unscrew Plug (74), insert a #10
screw in the thread of Plug (70), and pull to
remove. Using a small drift and hammer, from the
rear side of the head, drive Seat (88) out towards
the front of the head. (Fig. 9)
11. Pintail Deflector (21) can be pulled off barbed end
at rear of Pull Piston (11).
12. Unscrew End Cap (20) from Head (89) with 1 9/16
open end wrench. (Fig. 9)
13. Place Spacer (123112-1) on Pull Piston (11), and
screw Assembly/disassembly Bullet (123111-1)
onto piston. Tap or press piston assembly out of
head.
NOTE: This will push out front and rear gland
assemblies and wiper and wiper housing. (Fig. 2)
14. Remove Screw (67) from Throttle Arm (66).
Remove throttle arm. Pull Throttle Valve (36) out of
cylinder. Remove Spring (40). (Fig. 9)
64
7982(2)8081
SPACER
FILL TOOL
112465
LOCK-OUT POSITION
70
74
90
22 69(4)
1
75 7776
71
85 87 86
84 83
89
20
21
255
HUCK
FIG. 1
WARNING: Be sure air hose is
disconnected from tool before cleaning, or
performing maintenance. Severe personal
injury may occur if air hose is not
disconnected.

255 SERIES PNEUDRAULIC TOOLING (HK1014)
10
15. With a small punch and hammer, drive Roll Pin (5)
that retains the trigger from Handle (1). Remove
trigger pin (4). Remove ball end of Cable (2) from
throttle arm (66), and pull cable out of handle.
(Figure 9)
16. Remove Bleed Plug (64) from handle. (Fig. 1)
17. Hold tool inverted in vice. Unscrew three Button
Head Screws (45) with 1/8 hex key. (Fig. 3)
18. Remove Muffler End Cap (42), Bottom Exhaust
Gasket (46), Muffler (43) and O-ring (44). (Fig. 3)
19. Remove Retaining Ring (47) from Cylinder
Assembly (53). (Fig. 3) NOTE: Tap cylinder head
down into cylinder for easier removal of retaining
ring.
20. Screw Button Head Screws (45) into Cylinder
Head (49). Carefully pry under screws to remove
cylinder head.
21. Push air piston all the way down in cylinder, and lay
tool on its side. Hold Self-locking Nut (41) with a
9/16 socket and extension and with 7/64 hex key,
remove piston Screw (32). (Fig. 4 & 9)
22. Turn cylinder and handle upside down and secure
in a vise.
23. Grip Self-locking Nut (41) under Air Piston (51) with
pliers and pull piston and rod assembly from
handle and cylinder assembly. (Fig. 3 & 4)
24. With a 1 3/8 socket and extension, remove Gland
Assembly (54). Handle and cylinder will now
separate. (Fig. 3)
25. Push Hydraulic Piston (31) out of handle. Push out
from top to bottom.
26. To remove Polyseal (61) from Gland Assembly
(54), remove Retaining Ring (59) and Spacer (60).
(Fig. 9)
1
54
53
52
50
51
48
49
47
44
43
46
42
45
FIG. 3
9
91
92
15 14
10 (Note
orientation
of polyseal)
123111-1
ASSEMBLY
BULLET
123112-1
SPACER
HUCK 255
FIG. 2
D
DISASSEMBLY ISASSEMBLY ( (CONTINUED CONTINUED) )
CAUTION: Care must be given not to scratch
piston rod or cylinder during removal.
CAUTION: A plastic or wooden drift must be
used to avoid damaging the handle bore.

255 SERIES PNEUDRAULIC TOOLING (HK1014)
11
(Refer to Figures 1 thru 5 and 9.) Clean components with
mineral spirits, or similar solvent. Inspect for wear or damage
and replace as necessary. Replace all seals of disassembled
components. Use O-rings, Quad rings and Back-up rings in
Service Parts Kit 255KIT Smear LUBRIPLATE 130AA or
PARKER-O-LUBE on O-rings, Quad rings, Back-up rings and
mating parts to ease assembly. Assemble tool giving care not to
damage O-rings, Quad rings, or Back-up rings.
1. Holding handle inverted in a vice, place Cylinder (53) on
handle with Timing Pin positioned in matching hole.
Assemble Gland Assembly (54), screw it into handle, and
torque to 75-80 ft. lbs. using 1 3/8 socket wrench.
2. Push Air Piston/Rod assembly with Quad Ring (50) in place
into Air Cylinder until it bottoms at top of Cylinder. (Fig. 3)
3. Turn tool upright. Install Hydraulic Piston Assembly (31) (with
O-ring (33) and Back-up Rings (27) in place) in handle. Press
in from top of handle without damaging seals. (Fig. 4)
4. Push Screw (32) with O-ring (35) in place through Hydraulic
Piston (34) and screw into top of piston rod. Hold Self-
locking Nut (41) with 9/16 socket and extension and torque
Screw (32) using 7/64 hex key to 55-60 in. lbs. Torque Nut
(41) to 28-32 ft. lbs.
5. Hold handle in vise with bottom facing up. Push Cylinder
Head (49) with O-ring (48) in place squarely into cylinder.
Install Retaining Ring (47). (Figs. 3 & 9)
6. Position O-ring (44) and Muffler (43) on center of Cylinder
Head (49). Place Gasket (46) on Cylinder Assembly (53).
NOTE: Lip must face Muffler End Cap (42). Place Muffler
End Cap (42) on top of Gasket (46), and secure with 3 Button
Head Screws (45) using 1/8 hex key. (Fig. 3)
7. Turn tool upright. Drop Spring (40) into Throttle valve hole in
cylinder. Push Throttle Valve (36) with O-rings (37 & 39) 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 (66) onto ball end of Throttle Cable. Swing
arm until other end fits over throttle valve. Push Screw (67)
through Throttle Arm. Tighten with 5/32 hex key.
10. Reinstall Air Hose Assembly (38) if it was removed.
11. (If seat (88) is being replaced) Push Plug (70) (with O-ring
72 & Back-up Ring 25 in place) into head. Install Screw
(74). (Fig. 9)
12. Install O-ring (72) and Back-up rings (25) onto seat. Drive
seat and seal assembly in using soft drift taking care not to
damage ball seat surface. (Fig. 1 & 9)
13. Assemble Pull Piston (11) with new Seals (12 & 13).
Lubricate with LUBRIPLATE or PARKER SUPER-O-LUBE.
14. Thread Assembly Bullet (123111-1) onto Pull Piston (11) and
push entire assembly into head. (Fig. 2) NOTE: Spacer
(123112-1) is not needed for this procedure.
15. Push Front Gland (92) with O-ring (14), Back-up Ring (15),
Polyseal (10), Wiper Housing (91) and Wiper Seal (9) in
place onto Pull Piston (11). (Fig. 2)
16. Install O-rings (16 & 18) and Back-up Rings (17 & 19) on
Rear Gland (93). Push complete assembly into head,
screw in End Cap (20) and torque Cap to 55-60 ft.lbs.
17. Install O-ring (72) & Back-up Ring (25) on Plug (83). Install
Ball (87), Valve Guide (86), Sleeve (85), Spring (84) and
Plug (83) into head. (Fig. 1 & 9)
18. Install O-ring (65) on Plug (71). Install Ball (77), Guide (76),
Spring (75) and Plug into head.
19. Push Pintail Deflector (21) onto end of Pull Piston (11).
20. Place O-ring (65) on Bleed Plug (64) and screw assembly
into Handle (1). (Fig. 9)
21. Install O-rings (24 & 30) & Back-up Rings (25 & 29) on
Pull Gland (28), O-rings (24 & 26) and Back-up Rings (25
& 27) on Return Gland (23), and push Gland Assemblies
(22 & 90) into handle. Push Head (89) down on glands.
Place tool in a vise,
head down, and install
4 Screws (69) and
torque to 170 inch
pounds. (Fig. 5)
22. Tool is now assembled
and ready for Fill and
Bleed.
41
31
Piston
Assembly
FIG. 4
A
ASSEMBLY SSEMBLY
89
169(4)
22 90
FIG. 5

255 SERIES PNEUDRAULIC TOOLING (HK1014)
12
Equipment Required:
- Shop airline with 90 - 100 psi max.
- Air regulator
- Fill bottle, 120337, (supplied with tool).
- Large flat blade screwdriver
- Optional Stall Nut 120824
- Nose assembly
- Fasteners (Optional)
Preparation:
1. Install air regulator in
airline and set pressure to
20-40 psi.
2. Fill bleed bottle almost full
of DEXRON III - ATF or
equivalent. (Fig.6)
Refill tool only when red line on plunger drops below
the red line on the reservoir housing or when tool is
rebuilt. USE: AUTOMATIC TRANSMISSION FLUID
DEXRON III, OR EQUIVALENT.
Step 1
Screw Fill Tool P/N 112465 into Reservoir Plunger, pull
Plunger into Housing and lock Fill Tool in full forward
position by tilting handle (long side touching tool) and
locking in place. (Fig. 7)
Step 2
Remove Plugs (83) and (71) and all guides, springs
and balls from ports in head. Reinstall Plug (83) in
head in Relief Valve port (front of tool). (Fig. 7 & 8).
Step 3
Screw retaining nut onto head assembly. Screw Stall
Nut (optional see note:) onto Piston and tighten to
ensure full thread engagement. Back off retaining nut
until it engages stall nut. Check Piston location. Piston
must be all the way forward and locked with stall nut
and retaining nut. Note: If Stall Nut is not used, piston
must be pushed to the full forward position before
installing valves.
Step 4
Attach the tool air source momentarily to seat air piston
at bottom of cylinder. Disconnect tool. With fill port
facing up, (check valve on side) lay tool on its side.
Step 5
Install fill bottle in head fill port (check valve hole).
(Fig. 7 & 8)
Step 6
Connect tool to shop air regulated to 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.
Step 7
When air bubbles no longer appear in bottle, remove fill
bottle while tool is lying on its side.
Stall Nut
120824 8
HUCK
255
83
84
86
8785
71
76 77
75
1
Fill Tool
112465
Red Line
Indicator
64
FIG. 7
FILL
POINT
120337
Fill Bottle
Assembly
FIG. 6
F
FILL ILL AND AND B BLEED LEED
83
FIG. 8
WARNING: Avoid contact with hydraulic
fluid. Hydraulic fluid must be disposed of
in accordance with Federal, State and
Local Regulations. Please see MSDS for
Hydraulic fluid shipped with tool.
WARNING: Air pressure MUST be set to 20
to 40 psi to prevent possible injury from
high pressure spray. If plug (71) is
removed, fill bottle must be in place before
cycling tool.

255 SERIES PNEUDRAULIC TOOLING (HK1014)
13
F
FILL ILL AND AND B BLEED LEED ( (CONTINUED CONTINUED) )
Step 8
Install the check valve Ball (77), Guide (76) and Spring
(75). Replace the Plug (71). (Fig. 7) Note: When
cycling tool, always hold bottle up as shown in Figure 8
to prevent drawing in air from empty part of bottle.
Step 9
Turn tool so front of head faces you and remove the
relief valve Plug (83). Prior to removing Plug (83), it is
advisable to back out setscrew inside of plug by
approximately 1/2 turn counterclockwise. (See Figure
8a). This ensures that the Piston will remain in full-
forward position. Install relief valve Ball (87), Guide
(86), Sleeve (85) and Spring (84). Replace the Plug
(83).
Step 10
Unlock Fill Tool and check Reservoir red line. At this
point cycle tool with Stall Nut attached (Optional. See
note) and retaining nut locked in the full forward
position (“Dead Stall”). Reservoir should not drop below
the red line on the reservoir housing.NOTE: Dead
Stalling is not necessary if Optional Stall nut was not
used; just cycle tool.
Step 11
Re-lock the fill tool in out position.Lay tool on its left
side and remove Bleed Plug (64). Top off reservoir by
placing a few drops of oil in hole and wait for air bubbles
to escape. Push a pin or a scribe into hole to check for
trapped air bubbles. Replace plug. (Fig. 7)
Step 12
Unlock the fill tool and cycle tool as in step 10.
Reservoir may drop slightly. If so, repeat step 11 until,
when you touch the fill tool handle, it has no pressure
against it and it drops out of the lock position, and the
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 (if used). Install a nose
assembly and pull several fasteners to test function.
SECTION A-A
from Figure 9
Using a 3/32 Allen
wrench, loosen
setscrew inside Plug by
approx. 1/2 turn.
FIG. 8a WARNING:Failure to re-lock the 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.
S
STICKER TICKER L LOCATIONS OCATIONS
Partial view of Cylinder Base for Sticker Placement Clarity

255 SERIES PNEUDRAULIC TOOLING (HK1014)
14
5
4
3
2
1
54
53
22
90
31
24
25
26
27
23
24
25
28
29
30
27
32
33
34 35
24
25
26
27
23
24
25
28
29
30
27
32
33
34 35
See Detail
Below
54
58
57
56
55
59
60
61
62
66
67
68
65
64
63
69
(4)
89
PULL Gland Ass mbly
Gland Ass mbly
AA
RETURN Gland Ass mbly
Piston
Ass mbly
51
50
49
48
47
46
45 44 43 42
41
40
39
38
52
82 (2)
81
80 79 65
64
78
77
76
75
74
73
25
72
65
7170656484 85 86 87 88 25 72
83
25 72
SECTION A-A
20
16
11
891
92 12
13
15 14 17 93
18 19
6
7910
21
36
37
45
12
25
94
95
FIG. 9
A
ASSEMBLY SSEMBLY D DRAWING RAWING

255 SERIES PNEUDRAULIC TOOLING (HK1014)
15
ITEM DESCRIPTION Part No. QTY
1Handle & Sleeve Assembly 125641 1
2Cable 125643 1
3Throttle Lever 124333-2 1
4Trigger Pin 505496 1
5Roll Pin 500621 1
6Pintail Tube 126087 1
7Stop 110670 1
8Retaining Nut 117824 1
9Wiper Seal 505894 1
10 Polyseal 506160 1
11 Piston 126083 1
12 Back-up Ring 113251 2
13 O-ring 500851 1
14 O-ring 500823 1
15 Back-up Ring 126088 1
16 O-ring 505887 1
17 Back-up Ring 113253 1
18 Polyseal 129944 1
19 HUCK and Yr of Mfr Sticker 590517 1
20 End Cap 112491 1
21 Pintail Deflector 124211 1
22 Return Gland Assembly 112502 1
23 Return Gland 112427 1
24 O-Ring 500776 2
25 Back-up Ring 501082 6
26 O-Ring 500778 1
27 Back-up Ring 501084 3
28 Gland 112426 1
29 Back-up Ring 501087 1
30 O-Ring 500781 1
31 Hydraulic Piston Assembly 118865 1
32 Screw 117773 1
33 O-Ring 503768 1
34 Piston 117774 1
35 O-Ring 500773 1
36
Throttle Valve Assy (contains
Throttle Valve - not sold separately,
and Items 37, 39, and 40)
115558 1
37 O-Ring 504408 2
38 Air Hose Assembly 115436 1
39 O-Ring 504407 1
40 Spring 116272 1
41 Self-Locking Nut 121241 1
42 Muffler End Cap 116585 1
43 Muffler 115554 1
44 O-Ring 500777 1
45 Screw, Button Head 504127 3
46 Gasket 126941-2 1
47 Retaining Ring 505025 1
48 O-Ring 500873 1
49 Cylinder Head 111959 1
50 QUAD Ring 501460 1
51 Air Piston 100315 1
52 Piston Rod 112414 1
ITEM DESCRIPTION Part No. QTY
53** Cylinder Assembly 115556 1
54 Gland Assembly 116173 1
55 O-Ring 500786 1
56 QUAD Ring 501074 1
57 Back-up Ring 501090 1
58 O-Ring 500784 1
59 Retaining Ring 505939 1
60 Spacer 123904 1
61 Polyseal 506611 1
62 Gland 123903 1
63 Screw 502482 2
64 Bleed Plug 100309 3
65 O-ring 505438 4
66 Throttle Arm 127690 1
67 Screw & Bushing Assembly 127029 1
68 Guard 125656 1
69 Cap Screw 500102 4
70 Plug 120204 1
71 Plug 111068 1
72 O-ring 505446 3
73 Pin 120203 1
74 Screw 120129 1
75 Spring 100874 1
76 Guide 111067 1
77 Ball 502929 1
78 Seat 111139 1
79 Reservoir Plunger 112405 1
80 QUAD Ring 501408 1
81 Housing/Spacer Assembly 112403 1
82 Spring 505864 2
83 Plug 114530 1
84 Spring 505863 1
85 Sleeve 120127 1
86 Valve Guide 120128 1
87 Ball 502506 1
88 Seat 114528 1
89 Head Assembly 126079 1
90 Pull Gland Assembly 112501 1
91 Wiper Housing 123138 1
92 Front Gland 126081 1
93 Rear Gland 126085 1
94 Set Screw 502053 1
95 Silicone Cover 129710 1
96** Max Pressure & Flow Sticker 590350 1
97** CE Sticker 590351 1
98** HUCK Address Sticker 590347 1
** The 255 series tools come labeled with important
stickers which contain safety information. It is
necessary that these stickers remain on the tool and
are easily read. If any sticker becomes damaged or
worn, or when replacing a cylinder, the stickers must
be ordered and placed in the locations shown on
page 13 of this manual.
P
PARTS ARTS L LIST IST

255 SERIES PNEUDRAULIC TOOLING (HK1014)
16
Always check out the simplest possible cause of a
malfunction first. For example, an air hose not
connected. Then proceed logically, eliminating each
possible cause until the cause is located. Where
possible, substitute known good parts for suspected bad
parts. Use TROUBLESHOOTING CHART as an aid in
locating and correcting malfunction.
NOTE:
“Piston drift” is when the air piston is in the down
position, but the hydraulic pull piston is not in the full
follward position. This causes an out of sequence
condition.
1 Tool fails to operate when trigger is depressed.
a) Air line not connected
b) Throttle Valve O-rings (37 & 39), worn or
damaged.
c) Throttle Valve Cable (2) is broken.
2 Tool does not complete fastener installation and
break pintail.
a) Air pressure too low
b) Air Piston Quad-ring (50) worn or damaged.
c) Reservoir empty or low, refer to Fill and Bleed
section.
d) Air in hydraulic system, refer to Fill and Bleed
section.
e) Reservoir Springs (82) worn or damaged
f) Check for piston drift
3 Pintail stripped and/or swaged collar not ejected.
a) Check for broken or worn jaws in nose
assembly, refer to nose assembly data sheet.
b) Check for loose Retaining Nut (8)
c) Check for piston drift.
4Tool has piston drift.
a) Loose collet crashing into the front of the anvil,
this causes the relief valve to open allowing the
piston to drift. Tighten the collet and refer to Fill
and Bleed section.
b) Worn or damaged Return Pressure Relief Valve
in tool, inspect Seat (88), O-ring (72), Back-up
Rings (25), Steel Ball (87) and Valve Spring (84).
Replace if necessary.
c) Worn or damaged Piston Assembly (31); inspect
O-ring (33), O-ring (35) and Back-up rings (27).
Replace if necessary.
5Hydraulic fluid exhausts with air or leaks at base of
handle.
a) Worn or damaged Gland Assembly (54)
inspect Polyseal (61), O-rings (58 and 55),
Quad-ring (56) and Back-up ring (57) replace if
necessary.
6. Hydraulic fluid leaks at rear of Pull Piston (11)
a) Worn or damaged Rear Gland (93): Inspect
O-rings (16 and 18) and Back-up Rings (17
and 19). Replace if necessary.
7. Hydraulic fluid leaks at front of Pull Piston (11).
a) Worn or damaged Front Gland (92): Inspect
Polyseal (10), O-ring (14) and Back-up Ring (15).
Replace if necessary.
8. Pull Piston (11) will not return.
a) Throttle Valve (36) stuck: Lubricate O-rings
(37 & 39).
b) Throttle Arm (66), Cable (2) or Trigger (3)
binding.
9. Air leaks at air Cylinder Head (49).
a). Worn or damaged O-ring (48). Replace if
necessary.
A
ACCESSORIES CCESSORIES
Service Kit - 255KIT
(includes most consumable parts such as seals,
deflector, springs, etc.)
Stall Nut (Fig. 7) - 120824
Service Tool Kit - 126104
Includes:
Assembly Bullet (Fig.2) - 123111-1
Spacer (Fig. 2) - 123112-1
T
TROUBLESHOOTING ROUBLESHOOTING

255 SERIES PNEUDRAULIC TOOLING (HK1014)
17
L
LIMITED IMITED W WARRANTIES ARRANTIES
TOOLING WARRANTY:
Huck warrants that tooling and other items (excluding
fasteners, and hereinafter referred as "other items")
manufactured by Huck shall be free from defects in
workmanship and materials for a period of ninety (90)
days from the date of original purchase.
WARRANTY ON "NON STANDARD OR CUSTOM
MANUFACTURED PRODUCTS":
With regard to non-standard products or custom
manufactured products to customer's specifications,
Huck warrants for a period of ninety (90) days from
the date of purchase that such products shall meet
Buyer's specifications, be free of defects in
workmanship and materials. Such warranty shall not
be effective with respect to non-standard or custom
products manufactured using buyer-supplied molds,
material, tooling and fixtures that are not in good
condition or repair and suitable for their intended
purpose.
THERE ARE NO WARRANTIES WHICH EXTEND
BEYOND THE DESCRIPTION ON THE FACE
HEREOF. HUCK MAKES NO OTHER
WARRANTIES AND EXPRESSLY DISCLAIMS ANY
OTHER WARRANTIES, INCLUDING IMPLIED
WARRANTIES AS TO MERCHANTABILITY OR AS
TO THE FITNESS OF THE TOOLING, OTHER
ITEMS, NONSTANDARD OR CUSTOM
MANUFACTURED PRODUCTS FOR ANY
PARTICULAR PURPOSE AND HUCK SHALL NOT
BE LIABLE FOR ANY LOSS OR DAMAGE,
DIRECTLY OR INDIRECTLY, ARISING FROM THE
USE OF SUCH TOOLING, OTHER ITEMS,
NONSTANDARD OR CUSTOM MANUFACTURED
PRODUCTS OR BREACH OF WARRANTY OR FOR
ANY CLAIM FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES.
Huck's sole liability and Buyer's exclusive remedy for
any breach of warranty shall be limited, at Huck's
option, to replacement or repair, at FOB Huck's plant,
of Huck manufactured tooling, other items,
nonstandard or custom products found to be defective
in specifications, workmanship and materials not
otherwise the direct or indirect cause of Buyer
supplied molds, material, tooling or fixtures. Buyer
shall give Huck written notice of claims for defects
within the ninety (90) day warranty period for tooling,
other items, nonstandard or custom products
described above and Huck shall inspect products for
which such claim is made.
TOOLING, PART(S) AND OTHER ITEMS NOT
MANUFACTURED BY HUCK:
HUCK MAKES NO WARRANTY WITH RESPECT
TO THE TOOLING, PART(S) OR OTHER ITEMS
MANUFACTURED BY THIRD PARTIES. HUCK
EXPRESSLY DISCLAIMS ANY WARRANTY
EXPRESSED OR IMPLIED, AS TO THE
CONDITION, DESIGN, OPERATION,
MERCHANTABILITY OR FITNESS FOR USE OF
ANY TOOL, PART(S), OR OTHER ITEMS THEREOF
NOT MANUFACTURED BY HUCK. HUCK SHALL
NOT BE LIABLE FOR ANY LOSS OR DAMAGE,
DIRECTLY OR INDIRECTLY, ARISING FROM THE
USE OF SUCH TOOLING, PART(S) OR OTHER
ITEMS OR BREACH OF WARRANTY OR FOR ANY
CLAIM FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
The only warranties made with respect to such tool,
part(s) or other items thereof are those made by the
manufacturer thereof and Huck agrees to cooperate
with Buyer in enforcing such warranties when such
action is necessary.
Huck shall not be liable for any loss or damage
resulting from delays or nonfulfillment of orders owing
to strikes, fires, accidents, transportation companies
or for any reason or reasons beyond the control of the
Huck or its suppliers.
HUCK INSTALLATION EQUIPMENT:
Huck International, Inc. reserves the right to make
changes in specifications and design and to
discontinue models without notice.
Huck Installation Equipment should be serviced by
trained service technicians only.
Always give the Serial Number of the equipment
when corresponding or ordering service parts.
Complete repair facilities are maintained by Huck
International, Inc.
Certified to
ISO 14001:2004
Industrial
Products
Certified to
ISO 9001:2008
Industrial
Products

Call our friendly & knowledgeable factory trained service
technicians today & discover what makes us different!
800 563 1293
www.applifast.com