11
7/11 REV 10/14
HANDLE
To inspect air cylinder bore, remove o’ring (S12) and base cover (744124). Any further disassembly will require removal of the head
cylinder assy (713121) first. For complete disassembly, start by removing parts o’ring (S12) and base cover (744124). Next, holding
tool upright, remove four button-head cap screws (402479). Lift head cylinder assy (713121) from handle assy (744129), and set aside
o'ring (S832) and gasket (704129). Empty all hydraulic oil into an approved container and dispose of in accordance with all
environmental regulations applicable in your area. Place piston rod wrench (704149) down into top of power cylinder (743131) and
into the hex of piston rod assy (744136). While holding this wrench (704149), remove flexlock nut (400559) using a 7/16" socket
wrench. Still holding piston rod wrench (704149), remove air piston assy (744121) using packing plug wrench (704150), by turning
counterclockwise. When air piston assy (744121) is completely free from piston rod assy (744136), tap or push on the piston rod
wrench (704149) to eject air piston assy (744121) from bottom of the handle assy (744129). After removal of air piston assy (744121),
slide piston rod assy (744136) back up to the end of its travel. Using packing plug wrench (704150), remove packing plug (744118).
With packing plug (744118) removed, power cylinder (743131) can be removed by pushing on power cylinder tool (704151) when
inserted into top of power cylinder (743131).
To reassemble the handle assy (744129), reverse the above procedure, being certain that all o'rings are properly lubricated before
installation. Torque packing plug (744118) to 45 foot lbs. Attach the seal guide (704152) to the piston rod assy (744136) and tap the
piston rod assy (744136) through the packing plug (744118). Attach air piston assy (744121) and flexlock nut (400559). Torque flexlock
nut to 40 inch lbs. Attach air piston assy (744121) to piston rod assy(744136). With the piston rod assy (744136) in the down position,
fill oil passage on top of handle assy (744129) with automatic transmission oil, Dexron III or equivalent. When looking at top of handle
assy (744129), the oil passage is the hole that has a counterbore for o'ring (S832). Replace gasket (704129) and o'ring (S832), just
prior to replacing head cylinder assy (713121). (See Filling & Bleeding instructions).
AIR VALVE
WARNING
:
Disconnect tool from its air source before disassembly.
To disassemble, first disconnect tool from its air source. Remove pin (744149) and muffler (744143). Insert valve extractor (S1178)
into end of valve plug (744142) and pull it out. Using the same procedure, pull out valve spool assy (743142). NOTE: It should never
be necessary to remove valve sleeve (743144) unless the ports in the valve sleeve (743144) are plugged from contaminated air. If
ports are plugged, use needle nose pliers to grasp end of spring (744144), turning clockwise and pulling to dislodge from groove in
casting. NOTE: Valve spring tool (744151) will facilitate the proper installation of the spring (744144), valve sleeve (743144) can be
pulled out using valve sleeve removal tool (744152).
