8/14
7
FILLING:
1. Put the piston rod wrench (704149) into the top of handle assy (704132), pushing down firmly until piston rod ass’y (704138) is
completely in the down position.
CAUTION:
When forcing piston rod assembly downward, with head cylinder assy removed, hydraulic oil will eject forcibly from handle assy.
2. Fill oil passage and reservoir with Automatic Transmission Oil, Dexron III or equivalent. The reservoir is the area surrounding the
power Cylinder (751131). When looking at the top of the handle assy (704132), the oil passage is the hole that has a counterbore
for o’ ring (S832). Do not overfill causing oil to go in air passage hole.
3. Install o’ ring (S832), gasket (704129), button head cap screws (A-928) and manifold-handle (744303) to handle assy (704132)
keeping hydraulic hose (A-336) towards plug (704313) and torque cap screws (A-928) to 40 inch lbs.
4. Push piston (703607) full forward. Install gasket (704129) and o’ ring (S832) on manifold-head assy (744306). Assemble head
cylinder assy (703134) to manifold-head assy (744306) using socket head cap screws (400061 & 400066). Apply Loctite 242 to all
cap screws and torque to 40 inch lbs.
4.
5.
Remove pin and lever from lever ass’y (724017).
Coil tool up on bench and lay handle assy (704132) down on side so that the
hole on manifold handle (744303) marked #3 is to the bottom. Set head cylinder assembly (703134) over a small bucket or can.
Completely fill up fill bottle ass’y (745163).
6. Remove button head cap screw (402482) and stat-o-seal (S572) from manifold-handle (744303) hole #3 and manifold-head assy
(744306) hole #4. Connect fill bottle (745163) to manifold-handle (744303) hole marked #3.
7. In one continuous squeeze force oil into manifold-handle (744303) until oil starts to flow from bleeder hole marked #4 on
manifold-head assy (744306). While still squeezing the fill bottle ass’y (745163) use other hand to replace button head cap screw
(402482) and stat-o-seal (S572) on manifold-handle (744303) and torque to 40 inch lbs. This may require two people.
8. Remove fill bottle ass’y (745163) and replace stat-o-seal (S572) and button head cap screw (402482) on manifold-head assy
(744306) and torque to 40 inch lbs.
BLEEDING:
1.
Remove pin and lever from lever ass’y (724017).
Stand handle assy (704132) on floor, stretch hose and head cylinder assy (703134)
upward and lay flat on a table or bench. When bleeding tool always keep the head cylinder assy (703134) higher than the handle assy (704132).
2. Remove button head cap screw (402482) and stat-o-seal (S572) from hole marked #3 and attach air bleeder assy (704153) to man-
ifold-handle (744303) in an upright position.
3. Connect the tool to air supply and cycle tool 10 times holding the air actuator ass’y (704130) down for 2-3 seconds between
cycles to remove any air from the tool.
4. Disconnect air supply. Remove air bleeder ass’y (704153) from manifold-handle (744303) and replace with button head cap screw
(402482) and stat-o-seal (S572) and torque to 40 inch lbs.
5. Ensure air supply is disconnected. Remove button head cap screw (402482) and stat-o-seal (S572) from hole marked #4 manifold
-head assy (744306) and attach air bleeder ass’y (704153) in an upright position.
6. Connect air supply. Cycle tool 10 times removing any air bubbles.
7. Disconnect air supply. Remove air bleeder ass’y (704153) and replace button head cap screw (402482) and stat-o-seal (S572) and torque to 40 inch lbs.
8. Connect air supply. Cycle tool 5-6 times and check stroke of .780 (19.8 mm) (see diagram below). We recommend using dial calipers.
With the air actuator assy (704130) released, check dimension (A). Holding air actuator assy (704130) check dimension (B). If
stroke is not consistent within 1/64" (.0156) repeat bleeding steps 5-6.
9. Re-attach lever and pin to lever ass’y (724017).
.365 (9.3mm)
'A'
1.145 (29.1mm)
FILLING & BLEEDING PROCEDURE:
NOTE:
Air Bleeder Ass’y (704153) and Fill bottle Ass’y (745163) are required.
NOTE:
To replace a small amount of oil follow BLEEDING steps 5-6. Apply Loctite 242 to all cap screws.
WARNING:
Do not cycle tool without air bleeder assy (704153), or screw and stat-o-seal, installed in tool head. Severe personal injury could result.
CAUTION:
Before filling handle assy, air piston assy should be all the way down.
IMPORTANT:
Be sure to use thread sealant on all hydraulic fittings, Loctite® 30534 or similar Teflon® infused pipe dope is recom
mended.
CAUTION:
Teflon tape is an excellent thread sealer, however, if it is not properly applied, pieces may enter
the hydraulic system and cause malfunction and 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.
* FILLING & BLEEDING VIDEO AVAILABLE AT: www.gagebilt.com/bleeding.htm
