THIS
MODEL
HAS
BEEN
DISCONTINUED;
SEE
G686B
‐
S
FOR
REPLACEMENT
7
appropriate, to avoid cutting them. Always lubricate all O-rings. Just before placing the head sub-assembly onto the pistol
grip, see Fill and Bleed Instructions.
Insert release piston sub-assembly (28) into rear cap (30), making sure index pin in release piston sub-assembly
(28) drops into recess in rear cap (30).
Insert shift screw (26) into the release piston sub-assembly (28). Slip index washer (33) onto button head cap screw (34).
Engage threads of button head cap screw (34) with shift screw (26) and firmly tighten. Then turn button head cap screw (34)
counterclockwise to retract shift stop (22) fully into release piston (28). Ensure that the hex of the shift stop (22) is aligned with
the hex of the release piston sub-assembly (28).
Install piston cap (8) onto piston (14), threading seal guide (680A114) on head piston (14) to avoid damaging the O-rings as cap
(8) is threaded into place.
Hold shift piston (24) using the large hole in clamp wrench (680A48/49), being careful not to mar the smoothly ground surfaces
of the piston. Insert piston spring (23), and while compressing it, turn piston cap sub-assembly (8 and 14) into place with
clamp wrench (680A48/49) and firmly tighten.
Insert shift piston sub-assembly (24) into front of head cylinder (13) and thread on rear cap (30). Insert the four piston stops
(7), choosing every other hole. Thread on front end cap (3). Place head assembly in smooth jawed vise, clamping on hex of
rear cap (30), with front end cap (3) upward. Using the end cap socket wrench (680A173) and a handle extension,
tighten front end cap (3) to 150-180 ft.-lbs. (203-244 N-m) torque.
Replace adjuster ring (36), socket head cap screw (35), adjuster knob (37), and then the other socket head cap screw (35)
onto the back of the rear cap (30).
Replace the head sub-assembly onto the top of the pistol grip (83) being sure that O-rings (41) are properly
oriented.
Tighten the six socket-head cap screws (82) uniformly to prevent leakage.
Purge system of air using Cherry air bleeder (700A77) according to Fill and Bleed instructions.
P O W E R U N I T S U B - A S S E M B L Y
To completely disassemble the power unit,
disconnect tool from air line then use the following procedures.
Remove the six cap screws (96). As manifold assembly (100) is removed, hold upper portion of tool over a pan to catch oil
that will run out. Drain oil from head, hoses and inside of power unit. Dispose of oil according to environmental regulations.
Remove gasket (95) and O-ring (41).
Remove six flat head screws (57) on base using a 3/16 hex key, and, using a screwdriver, carefully pry power unit base (56)
out of power unit.
Use piston rod wrench (530A86) to push the power piston and rod sub-assembly (98) down.
Remove cotter pin (52). Engage and hold top of power piston and rod sub-assembly (98) with piston rod wrench (530A86) and
remove slotted nut (51) using 9/16" socket wrench. Then unscrew power piston and rod subassembly (98) until it disengages
from air piston (50).
Insert threaded end of power cylinder tool (530A88) into bottom of air piston (50). Using this as a handle, pull the air piston out of
the bottom of the tool.
Thread seal guide (530A81) onto end of power piston and rod sub-assembly (98) and push out through top.
Using packing plug wrench (530A83-3) together with a 1-1/4" socket wrench, remove packing plug (47) and lift out the
exposed O-ring (46).
Insert power cylinder tool (530A88) into top end of power cylinder (60) and force power cylinder with quad rings (61) out of the
bottom of the tool.
