15
4/12 Rev. 1/17
S/N: 3191 AND ABOVE
PLEASE CONTACT GAGE BILT FOR ALL OTHER SERIAL NUMBERS.
To inspect air cylinder bore, remove base cover (704125) and o’ring (S725). Any further disassembly will require removal of the head
cylinder assy (703109) first.
For complete disassembly.
1. Remove base cover (704125) and o’ring (S725).
2. Holding tool upright, remove four button-head cap screws (A-928) and lift head cylinder assy (703109) from handle assy (704132)
and set aside o'ring (S832) and gasket (704129).
3. Empty all hydraulic oil into an approved container and dispose of in accordance with all environmental regulations applicable in
your area.
4. Place piston rod wrench assy (704149) down into top of power cylinder (751131) and into the hex of piston rod assy (704138).
While holding this wrench, remove flexlock nut (400559) using a 7/16" socket wrench. Still holding piston rod wrench assy
(704149), remove air piston assy (704121) using packing plug wrench assy (704150), by turning counterclockwise.
5. When air piston assy (704121) is completely freed from piston rod assy (704138), tap or push on the piston rod wrench assy
(704149) to eject air piston assy (704121) from bottom of handle assy (704132).
6. After removal of air piston assy (704121), slide piston rod assy (704138) back up to the end of its travel. Using packing plug
wrench assy (704150), remove packing plug (704118).
7. With packing plug (704118) removed, power cylinder (751131) can be removed by pushing on power cylinder tool assy (704151)
when inserted into top of power cylinder (751131).
To reassemble the handle assy (704132)
1. Reverse the above procedure, being certain that all o'rings are properly lubricated before installation. Torque packing plug (704118)
to 45 foot lbs.
2. Attach the seal guide (704152) to the piston rod assy (704138) and tap the piston rod assy (704138) through the packing plug (704118).
3. Attach air piston assy (704121) and flexlock nut (400559). Torque flexlock nut to 40 inch lbs.
4. Attach air piston assy (704121) to piston rod assy (704138).
5. With the piston rod in the down position, fill oil passage on top of handle assy (704132) with automatic transmission oil, Dexron III or
equivalent. When looking at top of handle assy (704132) the oil passage is the hole that has a counterbore for (S832) o'ring.
6. Replace gasket (704129) and o'ring (S832), just prior to replacing head cylinder assy (703109). (See Filling & Bleeding instructions.)
Torque button head cap screws (A-928 ) to 40 inch lbs.
1. Remove nose assembly and adapter from tool before attempting disassembly of head assy.
2. Remove end cap (703114).
3. Push against threaded end of piston (703607) to slide it out of head cylinder assy (703109). Be careful not to damage threads
or cause burrs on polished piston (703607) surface.
The re-assembly sequence is the opposite of disassembly. (See Filling and Bleeding instructions.) Apply Loctite® #242 (Gage Bilt #A-1006)
and torque the button head cap screws (A-928) uniformly to 40 inch lbs. to prevent leakage around the gasket (704129).
WARNING
:
Disconnect tool from its air source before disassembly.
DISASSEMBLY
HEAD
HANDLE
1. Remove pin (704244) and muffler (704146).
2. Insert valve extractor (S1178) into end of valve plug (704145) and pull it out.
3. Using the same procedure, pull out valve spool assy (703142).
4. Use needle nose pliers to grasp end of spring (704141), turning clockwise and pulling to dislodge from groove in casting. Valve
spring tool assy (704262) will facilitate the proper installation of the spring (704141),
5. Valve sleeve (703139) can be pulled out using valve sleeve removal tool (704163).
AIR VALVE
