Arconic 202V User manual

Patent Pending
January 5, 2017
HK938
Makers of Huck®, Marson®, Recoil®
Brand Fasteners, Tools & Accessories
Instruction Manual
202 series
Pneudraulic Installation Tools
Declaration of Conformity
2
Safety Instructions
3
Specifications
4-5
Principle of Operation
6
Preparation for Use
6
Operating Instructions
7
Maintenance
7
Disassembly Instructions
8-10
Assembly Instructions
11-12
Fill and Bleed
13
Measuring Tool Stroke
14
Components Drawings
15-17
Kits and Accessories
18
Troubleshooting
18

2
202 series Pneudraulic Installation Tools (HK938)

3
202 series Pneudraulic Installation Tools (HK938)
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.
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 operated.
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.
Safety Instructions
GLOSSARY OF TERMS AND SYMBOLS:
- Product complies with requirements set forth by
the relevant European directives.
- Read manual prior to using this equipment.
- Eye protection is required while using this
equipment.
- Hearing protection is required while using this
equipment.
Notes: are reminders of required procedures.
Bold, Italic type, and underline: emphasize a specific
instruction.
WARNINGS: Must be understood to avoid
severe personal injury.
CAUTIONS: Show conditions that will damage
equipment or structure.

4
202 series Pneudraulic Installation Tools (HK938)
Specifications
Models
202 & 202L
STROKE: 0.75 in (1.90 cm)
WEIGHT: See model-specic drawings.
MAX AIR PRESSURE: 90 psi (6.2 bar)
MAX FLOW RATE: 8.5 scfm (241 l/m)
MAX OPERATING TEMP: 125° F (51.7° C)
PULL CAPACITY: 3889 lbs @ 90 psi
(17.3 kN @ 6.2 bar)
SPEED / CYCLES: 20 per minute
POWER SOURCE: Huck POWERIG®Hydraulic Unit
HOSE KITS: Use only genuine HUCK Hose Kits rated
@ 10,000 psi (689.5 bar) working pressure.
HYDRAULIC FLUID: Hydraulic uid shall meet
DEXRON®III, DEXRON VI, MERCON®, Allison C-4
or equivalent ATF specications. Fire-resistant uid
may be used if it is an ester-based uid such as
Quintolubric® HFD or equivalent. Water-based uid
shall NOT be used as serious damage to equipment will
occur.
WEIGHT: 5.1 lbs (2.31 kg)
DEXRON is a registered trademark of General Motors Corp.
MERCON is a registered trademark of Ford Motor Corp.
Quintolubric is a registered trademark of Quaker Chemical Corp.
Ø
Ø
10°
3.4
(8.7)
1.5
(4.0)
1.1
(2.8)
0.8
(2.0)8.6
(21.8)
11.5
(29.4)
5.4
(13.7)
4.1
(10.4)
Inches
(cm)

5
202 series Pneudraulic Installation Tools (HK938)
Models
202V* & 202LV*
Model
202B
Specifications (continued)
* MODEL FEATURE
The 202V and 202LV models have a Tubing and Slide
Assembly (P/N 128044): a ribbed “ON/OFF” vacuum-
regulating slide. When the tool is not in use, the OFF
position will prevent air loss. See Figure 15, for the
location of the assembly (pictured in the ON position) on
the tool.
WEIGHT: 5.4 lbs (2.45 kg)
Ø
Ø
10°
3.4
(8.7)
1.5
(4.0)
10.1
(25.8)
1.2
(3.1)
2.4
(6.3)
1.1
(2.8)
0.8
(2.0)
11.5
(29.4)
5.4
(13.7)
4.1
(10.4)
Ø
Inches
(cm)
Ø
Ø
10°
3.4
(8.7)
1.5
(4.0)
9.4
(23.9)
1.2
(3.1)
2.4
(6.3)
1.1
(2.8)
0.8
(2.0)
11.5
(29.4)
5.4
(13.7)
4.1
(10.4)
Ø
Inches
(cm)
WEIGHT: 5.4 lbs (2.45 kg)

6
202 series Pneudraulic Installation Tools (HK938)
The 202 series of tools ship with a plug in the air inlet
connector. The connector has 1/4-18 female pipe
threads to accept the air hose tting. Huck recommends
quick-disconnect ttings and a 1/4” inside-diameter air
hose. The air supply should be equipped with a lter-
regulator-lubricator unit, and access to a 90 psi (6.2 bar)
air supply capable of 8.5 scfm (241 l/m).
NOTE: Air quick-disconnect ttings and air hoses
are not available from Huck International, Inc.
1. Remove the shipping plug from air inlet connector
and add a few drops of an approved hydraulic uid.
2. Screw the quick-disconnect tting into the air inlet
connector.
3. Set the air pressure on the regulator to 90–100
psi, and connect the air hose to the tool. Press and
release the trigger a few times to cycle the tool.
4. Disconnect the air hose from the tool, and remove
the retaining nut. Select the proper nose assembly
for the fastener being installed.
5. Screw the collet assembly (including the lock collar
and shim if applicable) onto the spindle and tighten
with a wrench.
6. Slide the anvil over the collet assembly and into the
counterbore. Slide the retaining nut over the anvil,
and screw the nut onto the head.
7. Connect the air hose to the tool and install fasteners
in a test plate of proper thickness with proper size
holes. Inspect the fasteners.
If fasteners do not pass inspection, see
TroubleshooTing to investigate possible causes.
NOTE: On older nose assemblies with lock collars, use
Loctite® 243™ on collet threads, because the 202 pull
piston does not have staking holes. Refer to the nose
assembly drawings that shipped with nose assemblies.
Preparation for Use
CAUTION: Do not use TEFLON®tape on
pipe threads. Tape can shred, resulting in
malfunctions. Threadmate®is available in a
4oz. tube from Huck (P/N 508517).
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
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PULL STROKE
When the trigger is pressed, the throttle valve moves
down to the PULL position, and pressurized air is
directed to the bottom of the air piston, causing it to
move upward (as shown above). The air above the air
piston is exhausted and directed through the center of
the throttle valve and out the bottom of the tool.
As the hydraulic piston rod moves upward, a column
of uid is forced into head, which moves the pull piston
rearward. The attached nose assembly moves with the
pull piston to start fastener installation.
RETURN STROKE
When fastener installation is completed, the trigger is
released. Air pressure, with the assistance of a spring,
sends the throttle valve to the up (RETURN) position.
Pressurized air is re-directed to the top of the air piston
(see above), causing the air piston and hydraulic rod to
move downward.
The air from below the piston is exhausted through the
bottom of the tool, and springs force the pull piston to
return to its home position. The damper valve impedes
oil ow at pinbreak to prevent “tool kick.”
Principles of Operation
TEFLON is a registered trademark of E. I. du Pont de Nemours and
Company.
Threadmate is a registered trademark of Parker Intangibles, LLC.
Loctite is a registered trademark of Henkel Corporation, U.S.A.

7
202 series Pneudraulic Installation Tools (HK938)
GENERAL
The operating efciency of your tool is directly related
to the performance of the entire system. Regular
inspection and the immediate correction of minor
problems will keep the tool operating efciently,
and prevent downtime. A schedule of “preventive”
maintenance of the tool, nose assembly, hoses, trigger
and control cord, and POWERIG will ensure your tool’s
proper operation and extend its life.
NOTE: Huck tools should be serviced only by
personnel who are thoroughly familiar with its
operation.
- Service the tool in a clean, well-lighted area. Take
special care to prevent contamination of pneumatic
and hydraulic systems.
- Have available all necessary hand tools—standard
and special.
- Carefully handle all parts. Before reassembly,
examine them for damage and wear. Always replace
seals when a tool is disassembled.
- Disassemble and assemble tool components in a
straight line. Do NOT bend, cock, twist, or apply
undue force.
- Have the appropriate Service Parts Kit (202KIT or
202VKIT) available when servicing the tool; it includes
important consumable parts. Other components, as
experience dictates, should also be available. See
KiTs & Accessories.
For supplementary information, see TroubleshooTing,
and the DisAssembly and Assembly procedures in this
manual.
DAILY
- If a Filter-Regulator-Lubricator unit is not being used,
uncouple the air disconnects and add a few drops of
hydraulic uid or a light-weight oil to the air inlet of the
tool.
NOTE: If the tool is in continuous use, add a few
drops of oil in every 2–3 hours.
- Before connecting an air hose to the tool, bleed the
air lines to clear dirt or water.
- Check all hoses and couplings for damage and air
leaks; tighten or replace if necessary.
- Check the tool for damage and air or hydraulic leaks;
tighten, repair, or replace if necessary.
- Check the nose assembly for tightness and damage;
tighten or replace if necessary.
- Periodically, check the tool stroke. If the stroke is
short, add uid. For more information, see meAsuring
Tool sTroKe.
WEEKLY
- Disassemble, clean, and reassemble nose assembly
in accordance with applicable instructions.
- Check the tool and all connecting parts for damage
and uid/air leaks; tighten or replace if necessary.
Maintenance
Operating Instructions
BLIND FASTENER INSTALLATION
The fastener can be placed in either the work hole
or the end of the nose assembly. For both methods,
the tool and nose assembly must be held against the
work and at a right angle (90°) to it. Press and hold
the trigger until the fastener is installed and the pintail
breaks. Release the trigger.
MAGNA-GRIP®FASTENER INSTALLATION
Place the pin in the work-hole and place the collar over
the pin. See WARNINGS. (If the collar has only one
tapered end, that end must be out toward tool.) Hold
the pin in the hole. Push the nose assembly onto the
pin protruding from the collar until the anvil touches
the collar. Press and hold the trigger until the collar is
swaged and the pintail breaks. Release the trigger.
CAUTION: Remove excess gap from
between sheets so that enough of the pin-
tail protrudes from the collar that all of the
jaw teeth can grip the pintail grooves. Jaws
that are not fully gripping pintail grooves
will be stripped or broken.
WARNINGS:
Inspect tools for damage and wear before
using. Do not use if damaged or worn;
serious personal injury may occur.
Pulling a pin without a collar, or with collar
chamfer against workpiece, may result in
the pin becoming a high-speed projectile
when the pin grooves are stripped or the
pintail breaks off. Serious personal injury
may occur to anyone in the pin’s “ight
path.” This includes pins that ricochet.
Broken pintails eject from the deector
with speed and force. To reduce the risk of
serious personal injury, be sure the pintail
deector is directed away from all personnel.
Always use pintail bottles with models
202B and 202V. Replace damaged pintail
deectors and bottles.

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 identication, 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 uid into a
container. (Figure 1) Discard the uid.
4. Models 202 & 202L: Pull pintail deector 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 PinTAil boTTle/VAcuum
sysTem DisAssembly.
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 mufer
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 uid into a
container; discard the uid.
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.

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
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FIgure 1
504127 Buon
Head Screw (3)
128790
Boom 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
FIgure 2
continued...

9
202 series Pneudraulic Installation Tools (HK938)
HEAD/HANDLE
This procedure applies to models 202, 202B, 202L. For
component identication, see Figures 3, 4, & 14a.
NOTE: For 202V & 202LV, also see PinTAil boTTle/
VAcuum sysTem DisAssembly.
1. Unscrew end cap; remove spring, spacer, and wiper
seal. (Figure 3)
2. Thread the Polyseal Insertion Tool into the rear of
the handle/head. (Figure 3)
3. Slide spacer onto the piston.
4. Thread the Piston Assembly Tool onto the piston.
5. Push the piston and front gland assemblies out
the back of the handle/head. Allow clearance, with
stand-off, as the piston leaves the tool. (Figure 4)
6. Un-thread the Piston Assembly Tool and remove
Spacer from the piston. Re-thread the Piston
Assembly Tool onto the piston, then slide the front
gland assembly off the piston. (Figure 4)
7. Remove the Piston Assembly Tool from piston, and
remove the Polyseal Insertion Tool from the rear of
the head/handle.
8. Remove retaining ring , washer, and Polyseal from
the piston.
NOTE: Inspect the hydraulic piston for wear,
scoring, and damage; replace if necessary.
9. Unscrew adapter. (Figure 14a) Inspect all seals and
parts.
10. If trigger cable assembly is damaged, remove it by
driving out pin with a punch. Remove dowel pin to
disconnect the cable from the the trigger.
Disassembly (continued)
506653
Retaining Ring
506654
Washer
506160 Polyseal
(note orientaon)
505817
Wiper Seal
122432
Gland Cap
123757
Front Gland
500816
O-ring
501110
Back-up Ring
505818 Polyseal
(note orientaon)
Piston Assembly
123774 (202); 125495 (202L)
124258 (202B); 124258-1
(202V);
125494-1 (202LV)
FIgure 4
Piston Assembly Tool
123111-2 (202,
202B, 202V)
123111-4
(202L, 202LV)
Spacer
123112-2 (202,
202B, 202V)
123112-3 (202L, 202LV)
123761 Adapter
Handle Assembly
123766 (202, 202L, 202B)
128178 (202V, 202LV)
PRESS
SUPPORT /
STAND-OFF
Polyseal Inseron Tool
121694-202 (all models)
FIgure 3
continued...

10
202 series Pneudraulic Installation Tools (HK938)
Disassembly (continued)
PINTAIL BOTTLE/VACUUM SYSTEM DISASSEMBLY
This procedure is applicable to models 202V and 202LV
only; it should be used in conjunction with the previous
sections, generAl and heAD/hAnDle. For component
identication, see Figures 5, 6, & 15.
1. Reach through the window of pintail bottle and
remove retaining ring and washer. (Figure 5)
2. Remove pintail bottle, and then disconnect the tube
from Plug & Gasket Assembly. (Figure 15)
3. Remove adapter and Tubing and Slide Assembly.
4. Remove end cap and spring. (Figure 6)
5. Remove spacer and O-ring from the spring side of
the end cap.
6. Remove retaining ring, tube, wiper seal, washer, and
O-ring from the bottle side of the end cap.
7. Remove O-rings from inside the adapter and Tubing
and Slide Assembly. (Figure 15)
501007 Retaining Ring
and 506648 Washer
123577
End Cap
128044 Tubing & Slide Assembly
123784 Adapter
130692 Pintail Bole
FIgure 5
500778
O-ring
506492
Spring
124828
Washer
125577
End Cap
500807
O-ring
506648
Washer
506488
Wiper
Seal
502310
Retaining
Ring
128186
Tube FIgure 6

11
202 series Pneudraulic Installation Tools (HK938)
Assembly
HEAD/HANDLE
This procedure is for the assembly of the head/
handle of models 202, 202B, 202L. For component
identication, see Figures 7, 8, & 14a.
PRIOR TO RE-ASSEMBLING THE TOOL:
- Clean components with mineral spirits or a similar
solvent. Inspect for wear/damage and replace as
necessary.
- Replace all seals of disassembled components.
- Use the O-rings, Quad-rings, and Back-up rings from
Huck Service Parts Kits (P/N 202KIT or 202VKIT).
- When assembling the tool, take care not to damage
O-rings, Quad-rings, Back-up rings.
- Smear LUBRIPLATE®130-AA (Huck P/N 502723) or
SUPER-O-LUBE®(Huck P/N 505476) on rings and
mating parts to ease assembly.
TO RE-ASSEMBLE THE TOOL:
1. If removed, position cable assembly in trigger slot
and slide dowel pin through the holes in the trigger
and the cable assembly. Position the assembled
trigger in the handle and drive pin through the holes
in the handle and trigger. (Figure 14a)
2. Screw nose adapter into head and tighten.
3. Thread the Polyseal Insertion Tool (P/N 121694-202)
into the head.
4. Assemble piston, Polyseal, and retaining ring. (Note
the orientation of the Polyseal in Figure 7.)
5. Assemble front gland, O-ring, Back-up ring, Polyseal,
and gland cap. (Note the orientation of the Polyseal
in the upper part of Figure 7.)
6. Thread the Piston Assembly Tool onto piston. Slide
the complete gland assembly and wiper seal onto
piston.
7. Use a press to gently install the assembled
components through the rear of the tool. (Figure 8)
8. Remove the Piston Assembly Tool and Polyseal
Insertion Tool.
9. Install rear wiper seal into the end cap. (Figure 14a)
10. Slide spacer and spring into end cap, and then
thread end cap assembly into rear of head.
NOTE: For 202V and 202LV, also see PinTAil boTTle/
VAcuum sysTem Assembly.
123761 Adapter
PRESS
SUPPORT / STAND-OFF
Polyseal Inseron Tool
121694-202 (all models)
Handle Assembly
123766 (202, 202L, 202B)
128178 (202V, 202LV)
FIgure 8
Piston Assembly Tool
123111-2 (202, 202B, 202V)
123111-4 (202L, 202LV)
506653
Retaining Ring
506654
Washer
506160 Polyseal
(note orientaon)
505817
Wiper Seal
122432
Gland Cap
123757
Front Gland
500816
O-ring
501110
Back-up Ring
505818 Polyseal
(note orientaon)
Piston Assembly
123774 (202); 125495 (202L)
124258 (202B); 124258-1 (202V);
125494-1 (202LV)
FIgure 7
continued...

12
202 series Pneudraulic Installation Tools (HK938)
Assembly (continued)
GENERAL
This procedure is applicable to all 202 series tools. For
component identication, see Figures 2, 7, 14, & 15.
1. Secure head/handle upside-down in a soft-jaw vise.
(Figure 2) Place inverted cylinder assembly on
the base of the handle. (The timing pin maintains
orientation.)
2. Assemble gland assembly with new seals. (Note the
orientation of the Polyseal in Figure 7.) Apply Anti-
Seize Compound (P/N 508183) to the threads of
the gland assembly. Screw the gland assembly into
the head/handle and torque it to 50 ft.-lbs. using a
1-3/8” socket wrench.
3. Push bumper rmly over gland.
NOTE: The side of the bumper with two slots
must face the bottom of the tool.
4. Install Quad-ring onto the air piston.
5. Lubricate the piston rod. Press the assembled air
piston/rod into the cylinder just enough to allow
installation of the cylinder head.
6. Assemble O-ring onto cylinder head and then push
the cylinder head squarely into the cylinder, taking
care not to damage O-ring. Install the retaining ring;
align the screw holes with the mufer end cap.
7. Position mufer in center of cylinder head. Position
gasket on the cylinder. (Figure 2) Note the direction
of the lip in Figure 7.
8. Carefully position bottom plate on the cylinder.
NOTE: Make sure that the mufer is properly
positioned in the recess of the bottom plate.
(Figures 2 & 14)
9. Secure the bottom plate with three button-head
screws using a 1/8” hex key. (Figure 2)
10. Assemble O-rings on throttle valve. (Figure 14
Section C-C)
11. Place the tool upright on a level surface. Drop
spring into the throttle valve bore in cylinder, and
push the throttle valve into the cylinder.
12. Place the ball end of throttle cable into the end of
throttle arm, then slide the throttle arm into the slot
on the cylinder. (Figure 14)
13. Snap lever guard in place, and install pivot screw in
the cylinder to retain throttle arm.
14. Models 202 & 202L: Push pintail deector onto the
end cap. (Figure 14)
Model 202B: Position adapter and pintail bottle on
the end cap. Reach in the window of the pintail
bottle and install the retaining ring and washer.
(Figures 14 & 15)
NOTE: For 202V & 202LV, also see PinTAil boTTle/
VAcuum sysTem Assembly.
The tool is now assembled and must be lled with
hydraulic uid prior to use. See Fill AnD bleeD.
PINTAIL BOTTLE/VACUUM SYSTEM ASSEMBLY
This procedure is applicable to models 202V and 202LV
only; it should be used in conjunction with the previous
sections, generAl and heAD/hAnDle. For component
identication, see Figures 5, 6, & 15.
1. Assemble adapter and Tube and Slide Assembly
and new O-rings.
2. From the bottle side of end cap, install O-ring,
washer, wiper seal, wiper housing, and retaining
ring as shown in Figure 6.
3. From the spring side of the end cap, install O-ring,
spacer, and spring. (Figure 6) Screw the entire
assembly into the head; tighten.
4. Assemble the Tubing and Slide Assembly and
O-rings; slide the complete assembly onto the end
cap, and push the tube into the connector. (Figure
15)
5. Position adapter and pintail bottle on end cap.
(Figures 5 & 15)
6. Reach through the window of pintail bottle, and
install washer and retaining ring as shown in Figure
5.
LUBRIPLATE is a registered trademark of Fiske Brothers Rening Co.
SUPER-O-LUBE is a registered trademark of Parker Hannin Corp.

13
202 series Pneudraulic Installation Tools (HK938)
Fill and Bleed
This section documents the “bleed-&-ll” procedure. For
component identication, see Figures 9, 10, & 11.
REQUIRED EQUIPMENT
- DEXRON® III or equivalent ATF (See sPeciFicATions
for more information.)
- Shop air-line with 90–100 psi (6.2–6.9 bar) max.
- Air regulator
- Fill Bottle Assembly (P/N 120337, supplied with tool)
- Large at-blade screwdriver
- Stall Nut (P/N 124090 or 125340, optional)
- Nose assembly
- Fasteners (optional)
PREPARATION
- Install air regulator in
the air-line and set the
pressure to 20–40 psi
(1.4–2.8 bar).
- Add an approved hydraulic
uid to the ll point of the
ll bottle.
TO BLEED AND FILL THE
TOOL:
1. Lay the tool on its side
with the ll port facing up
and remove bleed plug from the ll port.
2. Connect the tool to the shop air. If uid is present,
hold the tool over a suitable container with ll port
facing into container. Cycle the tool several times to
drain old uid, air, and foam. (Figure 10)
3. Screw the ll bottle into the ll port.
4. Stand the tool upright on a bench. Trigger the tool
slowly (20–30 cycles), and bend the ll bottle at a
right-angle (90°) to the tool. (Figure 11)
When air bubbles stop accumulating at top of the
bottle, stop cycling the tool. When the trigger is
released, the pull piston returns to the idle position
(full-forward).
5. Disconnect the tool from the air-line. Lay the tool on
its side and remove the ll bottle. Top off the uid in
the ll port, and install and tighten the bleed plug.
6. Connect the air-line to the tool and measure the
stroke as described in meAsuring Tool sTroKe. If
the stroke is less than specied, remove the bleed
plug and add uid. Re-insert the bleed plug and
recheck the stroke.
7. Increase the air pressure to specications. Install
two fasteners to check the function and installation
in a single stroke, or cycle the tool with a stall nut
fully threaded onto the piston to load up the tool.
Measure the stroke again. Remove the plug and
add uid. Re-insert the plug and cycle and measure
again. Repeat this process until the stroke meets
the recommended specication.
WARNING: Avoid contact with hydraulic
uid. Hydraulic uid must be disposed of
in accordance with local regulations. See
MSDS for hydraulic uid shipped with tool.
120336
Fill Bole
Fill Point
120004 Cap
120337 Fill Bole Assy
FIgure 9
WARNING: Air pressure must be set at
20–40 psi (1.4–2.8 bar) to prevent possible
injury from high-pressure spray.
If bleed plug (55) is removed, the ll bottle
must be in place before cycling the tool.
CONTAINER
(Discard fluid)
FIgure 10
CAUTION: Purge all uid from the tool
before relling. The tool stroke will be
diminished if the uid is aerated.
For optimal performance, rell with a uid
that is recommended in sPeciFicATions.
FIgure 11

14
202 series Pneudraulic Installation Tools (HK938)
Measuring Tool Stroke


202L &202LV
1. Cycle the piston all the way forward and
measure X.
2. Cycle and hold the piston back and
measure Y.
STROKE = X-Y
FIgure 13


202, 202B, 202V
1. Cycle the piston all the way forward and
measure X.
2. Cycle and hold the piston back and
measure Y.
STROKE = Y-X
FIgure 12

15
202 series Pneudraulic Installation Tools (HK938)
Tool Base (all models)
116134-1 GLAND ASSEMBLY
125139 Gland
Housing
500786 O-ring
506566 *
Polyseal
(note orientaon)
123906 Spacer
506565
Retaining Ring
500784 O-ring
501090
Back-up Ring
501414
Quad Ring
Tighten and torque to 50 .-lbs.
507164 SWIVEL ASSEMBLY
SECTION C-C
500778 O-ring
500779
O-ring (2)
502274
Retaining
Ring
*These sckers are at the base of Cylinder
Assembly 125752; they MUST be purchased and
placed as shown if they become damaged, lost, or
unreadable, or if the Cylinder Assembly is replaced.
590350 *
CE Scker
590351 *
Max. Pressure
and Flow Scker
590347 *
HUCK Address
Scker
HUCK
123754
Throle Arm
115505-1
Throle Valve
504408
O-ring (2)
504407
O-ring
116272
Spring
C C
507164
Swivel Assy
125752 *
Cylinder Assembly
130725
Air Piston
506490
Retaining Ring
128790 Boom Plate
111959-1
Cylinder
Head
500869
O-ring
500903 O-ring
111803-1
Piston Rod
116134-1
Gland Assembly
Bumper
116408
Timing Pin
Muffler
Gasket
126941-4
Screw (3)
504127115554-1
Locknut
505420
Washer
506493
Pivot Screw
125118
SECTION A-A
A
A
FIgure 14

16
202 series Pneudraulic Installation Tools (HK938)
Tool Head 202 &202L
Polyseal
505818 *
Front
Gland
123757
Retaining Ring
506653
Washer506654
Polyseal506160 *
Spring506492
WARNING Scker
590240-1 **
End Cap125150
Spacer
124828
Wiper Seal
506488 *
Pintail Deflector
124211
123766 **
Handle
Assembly
Cable Assembly
116404-1
Rotatable Stop
120588
* Note orientaon of Wiper Seals and
Polyseals.
** WARNING scker (590240-1) MUST be
purchased and placed as shown when it
becomes damaged, lost, or unreadable, or
if Handle Assembly (123766) is replaced.
Dowel Pin505496
Trigger Pin500621
Trigger124333-1
Retaining Nut
111795
Adapter
123761
Wiper Seal
505817 *
Gland Cap
122432
Back-up Ring
501110
O-ring
500816
SECTION A-A
TOOL HEAD 202 & 202L
Top View
A
A
506576 Plug
& Gasket
Assembly
104293 Bleed
Plug Assembly
125117
Lever Guard
590517
Scker
123774 Piston
Assembly (202)
125495 Piston
Assembly (202L)
Shown is the construcon of
the 202 and 202L. See Figure
15 for 202B, 202L, and 202LV
construcon.
1
1
Piston Assemblies include: 506653
Retaining Ring, 506654 Washer,
and 506160 Polyseal.
1
FIgure 14a

17
202 series Pneudraulic Installation Tools (HK938)
Tool Head 202B, 202V, &202LV
* WARNING scker (590240-1)
MUST be purchased and placed
as shown if it becomes lost,
damaged, or unreadable, or if
the Handle Assembly is replaced.
506675 Tubing
Connector (V models)
590240-1 *
WARNING Scker
506488
Wiper Seal
(Note Orientaon)
124828
Washer
501007
Retaining
Ring
506628
Washer
SECTION A-A
128044 Tubing &
Slide Assembly
(V models)
Pintail Bole
130692 (V models)
123772 (202B)
Piston
125494-1 (202LV)
Piston
124258-1 (202V)
124258 (202B)
123770 End Cap &
Adapter Assembly
(202B)
500778
O-ring
500807
O-ring
506648
Washer
128186
Tube
502310
Retaining Ring
123784
Adapter
500790
O-ring (2)
123577
End Cap
Vacuum Units 202V and 202LV
PARTIAL SECTION A-A
FIgure 15

18
202 series Pneudraulic Installation Tools (HK938)
Troubleshooting
1. Tool fails to operate when trigger is pressed.
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. Worn or damaged air piston Quad-ring.
c. Tool is low on hydraulic uid. See the Fill AnD
bleeD section.
d. Air in hydraulic system. See the Fill AnD bleeD
section.
3. Pintail stripped and/or swaged collar not ejected.
a. Check for broken or worn jaws in nose
assembly. See Nose Assembly Data Sheet.
b. Check for worn anvil. See Nose Assembly Data
Sheet.
4. Hydraulic uid 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.
Replace if necessary.
5. Hydraulic uid leaks at rear of pull piston.
a. Worn or damaged piston Polyseal. Replace if
necessary.
6. Hydraulic uid leaks at front of pull piston.
a. Worn or damaged front gland. Inspect Polyseal,
O-ring, and Back-up ring. Replace if necessary.
7. Pull piston will not return.
a. Throttle valve stuck; lubricate O-rings.
b. Throttle arm, cable, or trigger binding.
8. Air leaks at air cylinder head.
a. Worn or damaged O-ring. Replace if necessary.
Kits & Accessories
Always check the simplest possible cause (such as a loose or disconnected trigger line) of a malfunction rst. Then
proceed logically, eliminating other possible causes until the cause is discovered. Where possible, substitute known
good parts for suspected defective parts. Use this Troubleshooting information to aid in locating and correcting
trouble.
KITS
serVice KiTs
202, 202B, 202L - 202KIT
202V, 202LV - 202VKIT
Assembly Tool KiTs
202, 202B, 202V - 123110-2
- Polyseal Insertion Tool - 121694-202
- Piston Assembly Tool - 123111-2
- Spacer - 123112-2
202L, 202LV - 123110-8
- Polyseal Insertion Tool - 121694-202
- Piston Assembly Tool - 123111-4
- Spacer - 123112-3
conVersion KiT
Convert 202 to 202V - 124173
- Tubing and Slide Assembly - 128044
- Vacuum Attach Adapter - 123784
- Pintail Collection Bottle - 130692
- End Cap Assembly - 123577
- Retaining Ring Ext - 501007
- Straight Connector - 506675
- Piston Assembly - 124258-1
- Flat Washer - 506628
ACCESSORIES
Stall Nuts
- 202, 202B, 202V - 124090
- 202L, 202LV - 125340
Fill Bottle Assembly -120337
Pintail Collection Bag (202, 202L) -125652
1/8” Hex Key
(use with Screw, 504127) - 502294
5/32” Hex Key
(use with Pivot Screw, 125118) - 502295
Retaining Ring Pliers - 502866

19
202 series Pneudraulic Installation Tools (HK938)
Limited Warranties
Limited Lifetime Warranty on BobTail® Tools:
Huck International, Inc. warrants to the original purchaser that
its BobTail® installation tools manufactured after 12/1/2016
shall be free from defects in materials and workmanship for its
useful lifetime. This warranty does not cover special order
/ non-standard products, or part failure due to normal wear,
tool abuse or misapplication, or user non-compliance with the
service requirements and conditions detailed in the product
literature.
Two Year Limited Warranty on Installation Tools:
Huck International, Inc. warrants that its installation tools and
Powerigs®manufactured after 12/1/2016 shall be free from
defects in materials and workmanship for a period of two years
from date of purchase by the end user. This warranty does
not cover special order / non-standard products, or part failure
due to normal wear, tool abuse or misapplication, or user
non-compliance with the service requirements and conditions
detailed in the product literature.
90 Day Limited Warranty on Nose Assemblies and
Accessories:
Huck International, Inc. warrants that its nose assemblies
and accessories shall be free from defects in materials and
workmanship for a period of 90 days from date of purchase by
the end user. This warranty does not cover special clearance
noses, or special order / non-standard product, or part failure
due to normal wear, abuse or misapplication, or user non-
compliance with the service requirements and conditions
detailed in the product literature.
Useful lifetime is defined as the period over which the
product is expected to last physically, up to the point when
replacement is required due to either normal in-service wear,
or as part of a complete overhaul. Determination is made on a
case-by case basis upon return of parts to Huck International,
Inc. for evaluation.
Tooling, Part(s) and Other Items not manufactured by
Huck:
HUCK makes no warranty with respect to the tooling, part(s),
or other items manufactured by third parties. HUCK expressly
disclaims any warranty expressed or implied, as to the
condition, design, operation, merchantability, or fitness for use
of any tool, part(s), or other items thereof not manufactured
by HUCK. HUCK shall not be liable for any loss or damage,
directly or indirectly, arising from the use of such tooling,
part(s), or other items or breach of warranty or for any claim
for incidental or consequential damages.
Huck shall not be liable for any loss or damage resulting from
delays or non-fulfillment of orders owing to strikes, fires,
accidents, transportation companies or for any reason or
reasons beyond the control of the Huck or its suppliers.
Huck Installation Equipment:
Huck International, Inc. reserves the right to make changes in
specifications and design and to discontinue models without
notice.
Huck Installation Equipment should be serviced by trained
service technicians only.
Always give the serial number of the equipment when
corresponding or ordering service parts.
Complete repair facilities are maintained by Huck International,
Inc. Please contact one of the offices listed below.
Eastern
One Corporate Drive Kingston, New York 12401-0250
Telephone [phone] FAX [phone]
Outside USA and Canada
Contact your nearest Huck International location (see
reverse).
In addition to the above repair facilities, there are Authorized
Tool Service Centers (ATSC’s) located throughout the United
States. These service centers offer repair services, spare parts,
Service Parts Kits, Service Tool Kits and Nose Assemblies.
Please contact your Huck Representative or the nearest Huck
International location (see reverse) for the ATSC in your area.

Arconic Inc. (NYSE: ARNC) creates breakthrough
products that shape industries. Working in close
partnership with our customers, we solve complex
engineering challenges to transform the way we fly,
drive, build and power.
Through the ingenuity of our people and cutting-
edge advanced manufacturing, we deliver these
products at a quality and efficiency that ensures
customer success and shareholder value.
Arconic Fastening Systems and Rings world-wide locations:
AMERICAS
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
800-278-4825
845-331-7300
FAX: [phone]
Carson Operations
900 Watson Center Rd.
Carson, CA 90745
800-421-1459
310-830-8200
FAX: [phone]
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PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
800-388-4825
254-776-2000
FAX: [phone]
Tucson Operations
3724 East Columbia
Tucson, AZ 85714
800-234-4825
520-747-9898
FAX: [phone]
Acuña Operations
Hidalgo #120
Parque Industrial Amistad
26220 Acuña Coahuila
Mexico
FAX: [phone]
TELEX: 1173530 LUKSME
EUROPE
Telford Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952-290011
FAX: [phone]
Us Operations
BP4
Clos D’Asseville
95450 Us par Vigny
France
33-1-30-27-9500
FAX: [phone]
FAR EAST
Melbourne Operations
11508 Centre Road
Clayton, Victoria
Australia 3168
03-764-5500
Toll Free: 008-335-030
FAX: [phone]
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Huck is Forever, For the Long Haul, The
Future of Fastening Technology, The Future of
Assembly Technology, The Future of Tooling
Technology, and Tools of Productivity are
service marks of Huck International. Huck
provides technical assistance regarding the use
and application of Huck fasteners and tooling.
NOTICE: The information contained in this
publication is only for general guidance
with regard to properties of the products
shown and/or the means for selecting such
products, and is not intended to create any
warranty, express, implied, or statutory;
all warranties are contained only in Huck’s
written quotations, acknowledgments, and/
or purchase orders. It is recommended that
the user secure specific, up-to-date data and
information regarding each application and/or
use of such products.
© 2017 Huck International, Inc.
1 Corporate Drive, Kingston, NY 12401 • Tel: [phone] • Fax: [phone]