15
202 Series Tooling (HK938) Alcoa Fastening Systems
13. Push Bumper (34) firmly over gland.
NOTE: The side of the bumper with two slots
must face toward the bottom of the tool.
14. Install Quad Ring (47) onto Air Piston (37).
15. Lubricate piston rod. Press assembled air
piston/rod into cylinder just enough to allow
installation of cylinder head (45).
16. Assemble O-Ring (46) onto Cylinder Head (45)
and then push Cylinder Head squarely into
cylinder taking care not to damage O-ring (46).
Install Retaining Ring (38). (Align screw holes
with muffler end cap)
17. Position Muffler (42) in center of cylinder head.
Position Gasket (39) on cylinder. ( Refer to Fig
2 & 7) Note direction of Lip
18. Carefully position Bottom Plate (41) on cylinder.
NOTE:
Make sure that the muffler is properly
positioned in recess of Bottom Plate (41) ( Fig 2
& 14).
19. Secure the bottom plate with the three Button
Head Screws (40) using 1/8 hex key (Fig. 2).
20. Assembly O-Rings (72 & 50) on Throttle Valve
(52) (Fig. 14 Section CC)
21. Place the tool upright on a level surface, drop
Spring (49) into throttle valve bore in cylinder
(35). Push Throttle Valve into cylinder.
22. Place ball end of Throttle Cable (2) into end of
Throttle Arm (53), then slide Throttle Arm into
slot on Cylinder (Fig. 14).
23. Snap Lever Guard (73) in place, and install
Pivot Screw (48) in cylinder to retain throttle
arm (53).
24. 202 & 202L:
Push Pintail Deflector (24) onto
End Cap (21).
202B: Position Adapter (64) and Pintail Bottle
(24) on End Cap and, by reaching through the
window of the Pintail Bottle, install Washer (63)
and Retaining Ring (62) (Figures 14 & 15).
202V & 202LV:
Please reference Disassembly
of Pintail Bottle and Vacuum System Procedure.
25. Tool is now completely assembled and needs to
be filled with oil. Please refer to the fill and
bleed section next.
Pintail Bottle/Vacuum 202V & 202LV:
(Refer to Figures 6 & 15 )
The following steps are for the assembly of the
2025V & 2025LV models only. Please use these
steps in conjunction with the General and
Head/Handle disassembly sections of this manual.
1. Assemble Adapter and Tube/Side Assembly
(70) and new O-Rings (65).
2. From bottle side of End Cap (21) install O-Ring
(69), Washer (71), Wiper Seal (23), Wiper
Housing (67) and Retaining Ring (66) as shown
in (Fig. 6).
3. From tool side of end cap install O-Ring (68),
Spacer (22) and Spring (19). (as shown in Fig.
6) Screw entire assembly into head and
tighten.
4. Assemble Tube/Slide Assembly and O-rings
(65), slide complete assembly onto End Cap
(21) and push tube into connector (54) (Fig.15).
5. Position Adapter (64) and pintail bottle (24) on
End Cap (21) (Fig. 5 & 15).
6. By reaching through the window of the Pintail
Bottle (24), install Washer (63) and Retaining
Ring (62) as shown in (Fig. 5).
A
A
SSEMBLY
SSEMBLY
-
-
ALL
ALL
MODELS
MODELS
continued
continued
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