2012 series Tooling
(HK969)
Alcoa Fastening Systems
10
The following procedure is for complete disassembly.
Disassemble only subassemblies necessary to check
and replace damaged or worn seals, wipers, back-up
rings and other components.
Always replace seals, wipers, and back-up rings of
disassembled sub-assemblies.
1. Disconnect tool from air source.
2. Unscrew Retaining Nut and remove nose assem-
bly.
3. Unscrew Bleed Plug (
Figure 7
), including O-ring,
from top of Handle/head. Turn tool over and allow
fluid to drain into container. Tool may be cycled to
clear tool more completely. Discard fluid.
4. Pull Pintail Deflector off End Cap.
5. Remove Throttle Arm Pivot Screw and lift out throt-
tle arm. Disconnect ball end of Cable Assembly
from throttle arm. (
Figures 8 & 9
)
6. Hold tool in vise with bottom up. Remove Button
Head Screws (3) with 1/8 hex key. Remove End
Cap and Gasket. Remove Muffler from end cap.
Remove Spring from Throttle Valve.
7. To loosen Cylinder Head Retaining Ring in
Cylinder, tap Cylinder Head with mallet. Remove
Retaining Ring.
8. Screw Button Head Screws back into Cylinder
Head, and carefully pull or pry on screws to
remove head.
9. To remove air piston from cylinder, pull on Locknut
with vise-grip pliers.
Note: Air piston and rod
should not be disassembled. If Locknut
loosens, apply LOCTITE #271 and tighten to 25-
30 ft. lbs.
10. Remove Bumper from Gland Assembly. Unscrew
gland with 1 3/8 socket wrench and extension bar.
11. Remove Retaining Ring from Gland. Pull out
Spacer and Polyseal.
12. Lift Cylinder from Handle/head.
13. Turn Handle/head over and drain fluid into contain-
er. Discard fluid.
14. Pull Throttle Valve out of Cylinder. Note:
Service on
Throttle Valve Bushings is not normally required.
15. Press out Lower Bushing and Upper Bushing. Use
square ended brass rods at least six inches long.
With proper diameter rod, press out lower bushing
first, and
then
press out upper bushing using a
larger size rod.
16.
2012:
Place handle/head securely in vise. Remove
End Cap with 15/16” open end wrench. Extract
Spring, Washer and Wiper Seal.
2012B or 2012V:
See Special Disassembly
Instructions in Figure 3 for 2012B and 2012V on
next page.
R
EMOVAL
OF
P
ISTON
AND
F
RONT
G
LAND
(
Figure 10
)
17. Thread Polyseal Insertion/removal Tool, 121694-
202, into Handle/head.
18. Slide Spacer, 123112-2, onto piston. Thread Piston
Assembly (bullet) Tool, 123111-2 onto piston.
continued
CAUTION:Do not scratch, nick or ding
Piston Rod. This will cause permanent
hydraulic leakage.
WARNING
Air hose must be disconnected before:
• Removing or attaching nose assembly.
• Cleaning tool and/or nose assembly.
• Replacing worn or damaged tool
components.
Tool may be activated if not disconnected
and cylinder is under pressure. Fingers
may be severely pinched/lacerated. Other
severe personal injury may result.
CAUTION:Only if air leakage is not cor-
rectable with new Throttle Valve Seals,
Bushings should be replaced in Cylinder.
CAUTION: If Piston Seals and Gland Seals
must be reused, help prevent damaging
them by installing optional Polyseal
Insertion/removal Tool (121694-202) in rear
of Handle/head.
D
D
ISASSEMBLY
ISASSEMBLY