Huck AEROBOLT 10256 User manual

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HUCK GUN –10256
The powerful Huck 10256 air gun designed for Ø 7.9 & 9.5mm (5/16”& 3/8”) diameter Huck® fasteners.
Made in the USA, the 10256 Huck gun is the best in its class lock bolt & structural rivet gun. When it’s Huck,
you know it’s proven technology that works. It features a high-quality aluminium alloy body, ergonomically
designed handle and soft-setting installation to reduce operator impact. This tool has been built tough for
the high-speed installation of Huck fasteners diameter sizes 7.9 mm (5/16") and 9.5 mm (3/8"). The 10256
provides optimum stroke for one-cycle installations, concentric (in-line) pull piston and a new front gland
design, allowing for easy piston removal.
* Nose assemblies sold separately.
* Additional hose connection required: min. 3/8”Air hose with fittings
Tool includes: Operating manual, pintail deflector, small
Hose w/ 1/4" NPT & BSP (British Standard Pipe) fittings,
bleed tool, fill bottle, adaptor tube, stall nut.
Huck Gun HG-10256 Specifications
Weight
5.0Kg
Air Pressure
6.2 –7.59 bar (90-100psi)
Stroke
22.35mm
Pulling Force
44.42kN @ 6.2bar (90psi)
Fastener Capacity
Huck bolts & Huck rivets 7.9mm (5/16”)
& 9.5mm (3/8”) with different noses

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Safety Instructions
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.

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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
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 whip-check
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.

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When the Trigger is depressed (1), the Throttle Valve
moves to the down position (2), and pressurized air is
directed to the bottom of the Air Piston, causing it to
move upward (3). The air above the Piston is
exhausted and directed through the center of the
Throttle Valve and out the bottom of the tool (4). The
Air Piston has a Rod and a Hydraulic Piston attached.
When the Air Piston rod moves upward, a column of
pressurized hydraulic fluid is forced up (5)
into the tool head, which moves the Pull Piston back (6).
The attached nose assembly moves with the Pull Piston
to start fastener installation. When fastener installation
is completed, the Trigger is released (7). Air pressure,
with the assistance of a Spring (8), causes the Throttle
Valve to return to its up position (9). Pressurized air is
re-directed to the top of the Air Piston, causing it, along
with the Hydraulic Piston Rod, to move downward (10).
The air from below the Air Piston is exhausted through
the bottom of the tool (11). As this occurs, hydraulic
pressure is reversed and the Pull Piston is returned
forward (12). A return pressure relief valve protects the
tool against pressure spikes. The reservoir replenishes
the hydraulic system as needed.
Specifications
POWER SOURCE:
110 psi MAX shop air
HOSE KITS:
Use only genuine HUCK Hose Kits
rated @ 10,000 psi working
pressure.
HYDRAULIC FLUID:
Hydraulic fluid shall meet
DEXRON®
III, DEXRON VI, MERCON, Allison C-
4 or equivalent ATF specifications.
Fire resistant fluid may be used if
it is an ester based fluid such as
Quintolubric HFD or equivalent.
Water based fluid shall NOT be
used as serious damage to
equipment will
occur.
WEIGHT: 11.1 lbs (5.03 kg)
MAX OPERATING TEMP:
125°F (51.7°C)
SPEED/CYCLES: 30 per minute
MAX FLOW RATE:
22.4 scfm (634 l/m)
MIN PULL CAPACITY:
9986 lbs (44.42 kN) @ 90 psi
MAX INLET PRESSURE:
110 psi (6.2 bar)
MIN STROKE:
.875 inches (2.22 cm)
.750 inches (1.91 cm) when used
with
Stroke Limiter 118362-1
Where the following trade names are
used in this manual, please note:
DEXRON is a registered trademark of
General Motors Corporation. Loctite is a
registered trademark of Henkel
Corporation, U.S.A. LUBRIPLATE is a
registered trademark of Fiske Brothers
Refining Co. MERCON is a registered
trademark of Ford Motor Corp. Never-
Seez is a registered trademark of Bostik,
Inc. Quintolubric is a registered
trademark of Quaker Chemical Corp. Slic-
tite is a registered trademark of LA-CO
Industries, Inc. Spirolox is a registered
trademark of Smalley Steel Ring
Company Teflon is a registered
trademark of E. I. du Pont de Nemours
and Company. Threadmate is a registered
trademark of Parker Intangibles LLC.
TRUARC is a trademark of TRUARC Co.
LLC. Vibra-Tite is a registered trademark
of ND Industries, Inc. USA.

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Preparation for Use
The Model 256 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 22.4 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. Apply TEFLON in stick form to threads of Air Hose,
and screw hose into the tool.
3. Set air pressure on regulator to 90-100 psi.
4. Screw air fitting (not supplied with tool) into Air
Hose and connect to air source. Quick disconnect
fitting into Air Inlet Connector, or screw quick
disconnect fitting into Air Inlet Connector, then
attach optional Air Hose supplied with tool.
5. Cycle tool a few times by depressing and releasing
trigger.
6. Disconnect air hose from tool.
7. Remove retaining nut and stop.
8. Select proper nose assembly for fastener to be installed.
9. Screw collet assembly, including lock collar and shim, if
applicable, onto spindle holding Hydraulic Pull Piston of tool
with 3/8 hex key. Wrench tight.
10. Slide nose assembly anvil over collet assembly and into
counterbore.
11. Slide tool’s Stop and Retaining Nut over nose assembly
anvil and screw Nut onto tool head.
12. Connect air hose to tool and install fastener(s) in a test
plate of proper thickness with proper size holes. Inspect
fastener(s).
NOTE: Threadmate® should be used on collet threads for
nose assemblies without lock collars. All other noses should
be staked.
Maintenance
NOTE: WARNING Sticker and HUCK Trademark Sticker
must be always in place and readable.
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 256KIT includes consumable parts
and should be available at all times. Other
components, as experience 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.
2. Check the tool and all connecting parts for damage or
oil/air leaks, tighten or replace if necessary.

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Operating Instructions
Failure to understand WARNINGS may cause serious personal injury. Failure to understand CAUTIONS may cause damage to structure and Tool.
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 facing toward tool, not next to workpiece.)
Hold pin and push nose assembly onto pin protruding
through collar until nose assembly anvil touches collar.
Press trigger and hold pressed 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. Tool and nose assembly must
be held against workpiece, and at a right angle to it. Press
trigger and hold it pressed 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.
Disassembly Procedure
NOTE: Disassemble only those 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 and remove nose
assembly.
3. (Figure 1) Insert Fill Tool through reservoir housing
and screw into Reservoir Plunger, locking it in the out
position.
4. Unscrew 4 Cap Screws with 5/32 hex key. Carefully
lift Tool Head straight up from Handle, and remove
Pull and Return Gland Assemblies. Remove seals from
glands.
5. Unscrew Relief Valve Plug from front of head.
Remove Relief Valve Spring, Guide, Sleeve, and Ball.
Using a small magnet is helpful.
6. Unscrew Reservoir Fill Plug. Hold over waste oil
container and release fill tool slowly.
7. Unscrew Reservoir Housing from head. Remove 2
Springs. Slide Reservoir Plunger from head. Remove
spacer and Quad Ring. A pick may be used to remove
the Quad Ring.
8. Unscrew Check Valve Plug from side of head.
21. Push Air Piston all the way into cylinder and lay tool on its

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Remove Check Valve Spring, Guide, and Ball. A small
magnet is helpful.
9. If Check Valve Seat (Figure 10) is damaged, contact
your HUCK representative. If Relief Valve Seat is
damaged, it can be removed as described in step 10.
NOTE: If seats are removed, they may not be reused;
they must be replaced.
10. Relief Valve Seat Assembly Removal Note: All parts
in check valve hole must be removed before Plug “A”
can be removed. (Figs. 1 & 10) Unscrew Screw “B”.
Insert a #10 screw in the thread of Plug “A”, and pull
to remove. Using a small drift and hammer, from rear
side of head, drive Relief Valve Seat Assy (Fig. 10) out
toward the front of the head.
11. Pintail Deflector can be pulled off barbed end at
rear of Hydraulic Pull Piston.
12. Unscrew Cylinder Cap from Cylinder/Head using a
1-3/4” open-end wrench.
13. (Fig. 2) Place Spacer on Hydraulic Pull Piston, and
screw Assembly/Disassembly Bullet onto piston. Tap
or press piston assembly out of head. This will push
out front and rear gland assemblies and wiper and
wiper housing.
14.(Fig. 11) Remove Throttle Arm Screw; then remove
Throttle Arm. Pull Throttle Valve out of cylinder, and
remove Spring.
15.(Fig. 10) With a small punch and hammer, drive
Trigger Pin from the Handle. Remove Cable Pin.
Remove ball end of Cable from Throttle Arm (Fig. 11),
and pull cable out of handle.
16. Remove Reservoir Fill Plug from handle. (Fig. 10)
17. (Fig. 3) Hold tool inverted in vice. Unscrew 3 Cap
Screws with 5/32 hex key.
18. Remove Muffler End Cap, Bottom Exhaust Gasket,
Muffler and O-ring.
19. Remove Retaining Ring from Cylinder Assembly. Tap
Cylinder Head down into Cylinder Assembly for easier
removal of Retaining Ring.
20. Screw Cap Screws into Cylinder Head, and carefully
pry under screws to remove Cylinder Head. (Figure 3)
side. Hold Self-locking Nut with a 9/16 socket and extension
and, with 7/64 hex key, unscrew Intensifier Piston Screw.
22. Turn cylinder and handle upside down and secure in a
vise.
23. Grip Self-locking Nut under Air Piston with pliers and
pull piston and rod assembly from handle and cylinder
assembly.
24. With a 1 3/8 socket and extension, remove Main
Gland Assembly. Handle and cylinder will now separate.
25. To remove Polyseal from Gland Assembly, remove the
Gland Assembly Retaining Ring and Spacer first.
26. Using a soft drift, push Intensifier Piston out of handle.
27. To service handle sleeve and handle, use a blunttipped
punch to gently tap sleeve from top of handle through the
bottom. Inspect sleeve for damage or wear and replace if
necessary. Service O-ring inside handle bore.

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Assembly
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 (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 Relief Valve Seat Assy is being replaced, 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 all seals, Housing, and
Wiper in place, over Assembly Bullet and onto Pull
Piston. Push entire gland/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.
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.

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Fill and Bleed
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
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.
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.

Page 10 of 12
Head/Handle Components

Page 11 of 12
Air Cylinder Components

Page 12 of 12
Accessories
Stroke Limiter - 118362-1
Reduces stroke to .750 inches (1.91 cm)
Stall Nut - 120824
Pintail Collection Bag - 125655
Service Tool Kit - 126104
Includes:
Piston Assembly Bullet (Fig. 2) - 123111-1
Spacer (Fig. 2) - 123112-1
Troubleshooting
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 this section 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
forward 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 worn or damaged.
c) Throttle Valve Cable is broken.
2 Tool does not complete fastener installation and break
pintail:
a) Air pressure too low
b) Air Piston Quad Ring 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 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
c) Check for piston drift.
4 Tool has piston drift:
a) Loose collet crashing into the front of the anvil 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, O-ring, Back-up Rings, Steel Ball
and Valve Spring. Replace if necessary.
c) Worn or damaged Intensifier Piston Assembly:
Inspect O-rings and Back-up Rings, and replace if
necessary.
5 Hydraulic fluid exhausts with air or leaks at base of
handle.
a) Worn or damaged Gland Assembly: Inspect Polyseal,
O-rings, Quad Ring, and Back-up Ring, and replace if
necessary.
6. Hydraulic fluid leaks at rear of Pull Piston
a) Worn or damaged Rear Gland: Inspect O-rings and
Back-up Rings, and replace if necessary.
7. Hydraulic fluid leaks at front of Pull Piston.
a) Worn or damaged Front Gland: Inspect Polyseal
and replace if necessary.
8. Pull Piston will not return.
a) Throttle Valve stuck: Lubricate O-Rings.
b) Throttle Arm, Cable, or Trigger binding.
9. Air leaks at Air Cylinder Head.
a) Worn or damaged O-Ring. Replace if necessary.