9
REV. 2/14
HEAD
WARNING:
DISPOSE OF HYDRAULIC OIL IN ACCORDANCE WITH ALL ENVIRONMENTAL LAWS AND
REGULATIONS APPLICABLE IN YOUR AREA.
Disconnect hydraulic hoses and air line from adapter-handle (745303) and drain hoses. Push piston (204203) back to
rear of the cylinder (204300) to empty all oil from the tool. Push piston ass’y (204203) to the front of the cylinder
(204300).
Unscrew socket head cap screw (206118) from retaining ring (206117) use a spanner wrench to remove retaining ring.
Push piston ass’y (204203) back until cylinder cap ass’y (206115) falls out of cylinder (204300). Push piston ass’y
(204203) out the rear of the cylinder (204300). Using a small blunt object, remove o'rings and back-up rings from
components.
Clean parts mineral spirits or other o'ring compatible solvent being sure to clean o'ring grooves. Inspect components
for scoring, excessive wear or damage.
Reassembly sequence is opposite of disassembly. Coat hose fitting threads with a non-hardening Teflon® thread
compound such as Slic-tite® (GAGE BILT part no. 403237).
IMPORTANT:
Be sure to use thread sealant on all hydraulic fittings, Loctite® 30534 or similar Teflon® infused pipe
dope is recommended.
CAUTION:
Teflon tape is an excellent thread sealer, however, if it is not
properly applied, pieces of Teflon may enter the hydraulic system and cause malfunction or damage.
Use 1 1/2 wraps of tape on each thread. Cut off all loose tape ends. Tighten until fitting feels snug and
then go 1/2 to a full turn past that point.
CAUTION:
Over tightening can easily distort the threads.
HANDLE
To inspect air cylinder bore, remove only parts (744124) . Any further disassembly will require removal of the handle
adapter first.
For complete disassembly, start by removing socket head cap screws (A-928). Lift adapter-handle (745303) from
handle (744129) and set aside o'ring (S832) and gasket (745124). Empty all hydraulic oil into a container.
Place piston rod wrench (745155) down into top of handle (744129), into the slot of piston rod assembly (745344) and
remove nut (400559) then unscrew and remove piston rod assembly (745344) from air piston ass’y (744121). Insert
threaded end of power cylinder assembly tool (704151) into bottom of air cylinder and remove air piston ass’y (744121).
After removal of air piston ass’y (744121), slide piston rod ass’y (745344) back up the end of its travel. Using packing
plug wrench (704150) remove packing plug (744118). With packing plug removed, power cylinder (745331) can be
tapped out by lowering power cylinder tool 704151 down into top of handle onto top of cylinder.
To reassemble the handle (744129), reverse the above procedure, being certain that all o'rings are properly lubricated
before installation. Attach the seal guide (704152) to the piston rod ass’y (745344) and with a mallet, tap the piston rod
ass’y (745344) through the packing plug (744118).
AIR VALVE
To disassemble, first disconnect tool from its air source. Remove pin (744149) and muffler (744143). Thread valve
extractor (S1178) in end of valve plug (744142) and pull it out. Using the same procedure, pull out valve spool ass’y
(743142). NOTE: It should never be necessary to remove valve sleeve (743144) unless the ports in the valve sleeve are
plugged from contaminated air. If it is suspected that the ports are plugged up, use needle nose pliers to grasp end of
spring (744144), turning clockwise and pulling to dislodge from groove in casting. With spring (744144) removed, valve
sleeve (743144) can be pulled out using valve sleeve removal tool (744152) .
