8
202 series Pneudraulic Installation Tools
(HK938)
Disassembly
WARNING: Disconnect the air hose
from the tool before performing any
maintenance. Serious personal injury could
result if the air hose is connected.
GENERAL
This procedure is for the complete disassembly of
all
202
series of tools. Disassemble only those components
necessary to replace damaged O-rings, Quad-rings,
Back-up rings, and worn or damaged components. For
component identification, see Figures 1, 2, 5, & 14.
1.
Disconnect the tool from the air source.
2.
Unscrew retaining nut; remove nose assembly.
3.
Unscrew the bleed plug from top of the handle/
head. Turn over the tool and drain the fluid into a
container. (Figure 1) Discard the fluid.
4. Models
202
&
202L
: Pull pintail deflector off the end
cap. (Figure 2)
Models
202B
: Reach in the window of pintail bottle
and remove the retaining ring and washer; then
remove the pintail bottle and adapter. (Figure 5)
Models
202V
&
202LV
: See
P
inTAil
b
oTTle
/V
Acuum
s
ysTem
D
isAssembly
.
5.
Remove throttle arm pivot screw and lever guard.
Lift out throttle arm, and disconnect ball end of
cable assembly from it.
6.
Secure the tool in a vise, upside-down. (Figure 2)
Remove button-head screws with a 1/8” hex key.
Remove end cap and gasket, and remove muffler
from the end cap. Remove spring from the throttle
valve. (Figure 14)
7.
Tap down cylinder head with a soft mallet (to take
pressure off the ring), and remove retaining ring.
(Figure 2)
8.
Screw button head screws back into the cylinder
head, and carefully pry on the screws to remove the
head. Remove O-ring.
9.
Pull on lock nut with vise-grips to remove the air
piston from cylinder. Remove Quad-ring.
10. Remove bumper from gland assembly. Unscrew
gland assembly with a 1-3/8” socket wrench and
extension.
11.
Remove retaining ring from gland, and then pull out
spacer and Polyseal. (Figure 2) Remove O-rings,
Quad-ring
, and Back-up ring.
12.
Lift cylinder from handle/head. (Figure 2)
13.
Turn over the tool and drain the fluid into a
container; discard the fluid.
14.
Remove throttle valve from air cylinder, and remove
O-rings. (Figure 2)
CAUTION: Always use a soft-jaw vise to
avoid damaging the tool.
CAUTION: Take care to not scratch the
piston rod or cylinder when removing.
F
Igure
1
504127
Button
Head Screw (
3
)
128790
Bottom Plate
126941-1
Gasket
115554-1
Muffler
500869
Cylinder
Head O-ring
505420
Locknut
506493
Washer
130725
Air
Piston
Timing Pin
500901
O-ring
116408
Bumper
506490
Retaining Ring
123752
Cylinder Assy.
(
Figure 14
)
111959-1
Cylinder
Head
116134-1
Gland Assy.
(
Figure 14
)
111803-1
Piston Rod
123766
Handle
Assembly
125150
End
Cap
124211
Pintail
Deflector
F
Igure
2
continued...