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E N G L I S H
over the *Piston Seal Sleeve and into the Piston seal groove. Reasonable force is required to expand and insert the outer
sealing ring on the Piston, so the use of a press or vice is necessary.
•
Remove the *Piston Seal Plunger and the *Piston Seal Sleeve from the Piston 1. Lubricate the *Piston Bullet, Piston shaft
and Piston Seal 32 with Molykote® 111 grease.
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Screw the *Piston Guide Sleeve fully into the rear of the Body 2. Lubricate the bores in both the Body and the *Piston
Guide Sleeve with Molykote® 111 grease.
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Connect the spare *Quick Coupler - Female to the Quick Coupler - Male 10 on the Hydraulic Hose – Pull 19. This will
allow air to be released from the pull side Piston 1 when inserting the Piston.
•
Insert the assembled Piston 1 into the rear of the Body 2 and through the assembled Front Seal Gland 16. Push the
Piston into the fully forward position until it stops against the Front Seal Gland. Hydraulic oil will be expelled from the
Hydraulic Hose – Pull 19.
•
Remove the spare *Quick Coupler - Female from the Quick Coupler - Male 10 on the Hydraulic Hose 19. Remove the
*Piston Guide Sleeve from the rear of the Body 2.
•
Slide O-Rring 33 over the End Cap 6 and into the external groove. Insert the Spiral Back-up Ring 34 in the same groove,
behind the installed O-Ring. Refer to the General Assembly and Parts List for the correct orientation of the O-Ring and
Spiral Back-up Ring.
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Insert O-Ring 26 over the rear of the End Cap 6 and into the rear groove.
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Clamp the tool handle in a vice with soft jaws so that the tool is pointing nose down.
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Lubricate the surface and leading edge of the Body 2 bore into which the End Cap 6 is to be installed with Molykote®
111 grease.
•
Fill the rear of the Body 2 with Enerpac® HF hydraulic oil. Oil level should be just above the rear inlet bore into the Body.
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Connect the spare *Quick Coupler - Male to the Quick Coupler - Female 11 on the Hydraulic Hose - Return 18. This will
allow air to be released from the return side of the Piston when inserting the End Cap 6.
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Lubricate both the internal thread in the Body 2 and the external thread on End Cap 6 with MolyLithium Grease.
•
Insert the End Cap 6 into the rear of the Body 2, taking care not to damage the O-Ring 33 and Spiral Back-up Ring 34 on
the Body threads. Screw the End Cap 6 fully into the rear of the Body using the *End Cap Assembly Tool. In doing so, a
small amount of oil will be expelled from the Hydraulic Hose - Return 18.
•
Remove spare *Quick Coupler - Male from the Quick Coupler - Female 11 on the Hydraulic Hose – Return 18.
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Insert O-Ring 26 into the groove at the front end of the Body 2.
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Screw the Collet Adapter 37 on to the Piston 1 until the front face is fl ush with the end of the Piston. Align the hole in
the Collet Adapter with the slot in the end of the Piston and then insert Locking Pin 38.
•
Prime the placing tool as described in Preparation for Use on page 11.
Hose Assembly:
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Remove the two Screws 9 from the Hose Clamp 14 using a 3.0 mm Allen Key. Remove the Hose Clamp and Clamp Insert
25 from the Protective Sleeve 24 and Hydraulic Hoses - Return 18 and Pull 19.
•
Using the small fl at screwdriver prize the Handle Gator 8 from the handle mouldings 12 and 13. Pull the Handle Gator
over the Protective Sleeve 24, Hydraulic Hoses-Return 18 and Pull 19 and remove.
•
Using a 3.0 mm Allen Key (and 7.0 mm spanner on bottom nut) unscrew the fi ve screws 17 and 22 holding handle
mouldings 12 and 13 together and remove.
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The trigger 7 is soldered to control cable. Remove this assembly from the handles 12 and 13. The cable gland 21 is part
of this assembly.
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Cut the Cable Tie 20 and slide back the Protective Sleeve 24 to expose the fi ttings on the Hydraulic Hoses - Return 18
and Pull 19. The Hydraulic Hoses can be removed from the Body 1 using 12 mm and 14 mm spanners.
•
The Quick Couplers - Male 10 and Female 11 can be removed from the Hydraulic Hoses – Pull 19 and Return 18 using
18 mm and 24 mm spanners.
Assemble in reverse order to dismantling noting the following points:
•
Prior to assembly clean all threads on the Quick Couplers – Male 10 and Female 11 and the Hydraulic Hoses - Pull 19
and Return 18. Then apply two to three layers of 10 mm PTFE tape to the male threads on both of the Hydraulic Hoses.
•
Once assembled, prime the tool as per the instructions in section 3.2.
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