Instruction manual

MODEL 2025 TOOL ALCOA FASTENING SYSTEMS
13
7. Install assembled components in gently from rear of
tool using a press as shown in (Fig. 8).
8. Remove Piston Assembly Tool (123111-2 or 123111-4)
and POLYSEAL Insertion / removal (121694-2025)
Tool.
9. Install Rear Wiper Seal (23) into End Cap (21) (Fig.
14).
10. Slide Spacer (22) and Spring (19) into End Cap (21)
and then thread End Cap assembly into rear of Head.
NOTE:
For 2025V please reference Assembly of Pintail Bottle
and Vacuum System procedure. (Refer to Figures 5, 6
& 10)
General:
(Refer to Figures 2 & 9)
11. Hold Head/Handle (1) inverted in vice (with soft jaws).
Place inverted Cylinder Assembly (35) on base of
handle. Timing pin maintains orientation.
12. Assemble Gland assembly (25) with new seals (Fig.
9). Note orientation of polyseal. Apply VIBRATITE
(Huck P/N 505125) to threads of Gland Assembly.
Screw gland into head/handle and Torque to 75-80 ft.
lbs. using 1 3/8 socket wrench.
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 & 9)
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 (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. 9).
23. Snap Lever Guard (73) in place, and install Pivot
Screw (48) in cylinder to retain throttle arm (53).
24. For 2025 & 2025L: Push Pintail Deflector (24) onto
End Cap (21).
For 2025B & 2025LB: 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).
For 2025V & 2025LV: 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 2025V & 2025LV:
(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).