7
REV. 10/14
S/N: 2269 AND ABOVE
PLEASE CONTACT GAGE BILT FOR ALL OTHER SERIAL NUMBERS.
FILLING AND BLEEDING TOOL
NOTE:
Air bleeder assy (704153) is required.
WARNING:
Do not cycle tool without air bleeder assy (704153), or the button head cap screw (402482) and stat-o-seal (S572),
installed in the head cylinder assy (743108). Severe personal injury may result.
CAUTION:
Before filling handle assy (744129), the air piston assy (744121) should be all the way down.
CAUTION:
When forcing piston rod assy (744136) downward with head cylinder assy (743108) removed, hydraulic oil will
eject forcibly from handle assy (744129).
CAUTION:
Use CAUTION when removing button head cap screws (402482), stat-o-seals (S572) and air bleeder assy (704153).
Hydraulic oil may be under pressure
.
WARNING:
Failure to follow these instructions carefully may result in severe personal injury
To replace a small amount of oil in the tool, attach the air bleeder assy and connect tool to air line. Cycle tool ten times. Disconnect
air, remove the air bleeder assy, and reinstall the cap screw. This will ensure the removal of any air from the hydraulic system and its
replacement with oil.
* FILLING & BLEEDING VIDEO AVAILABLE AT:
www.gagebilt.com/bleeding.htm
Should it become necessary to completely refill the tool (such as would be required after tool has been dismantled and reassembled),
take the following steps after depressing air actuator assy
AND DISCONNECTING THE AIR SUPPLY:
1. Remove (4) button head cap screws (402479) and head cylinder assy (743108) from handle assy (744129). Slowly push piston (743407)
completely forward.
CAUTION:
Oil may leak from bottom of head cylinder assy (743108).
2. Fill handle assy (744129) and the oil passage on top of handle assy (744129) with automatic transmission oil, Dexron III or
equivalent. When looking at the top of the handle assy (744129) , the oil passage is the hole that is counterbored for o'ring (S832).
3. Replace head cylinder assy (743108) with care, ensuring gasket (704129) and o'ring (S832) are properly installed. Apply Loctite
242 to all four button head cap screws (A-928) and torque uniformly to 40 inch lbs. to prevent leakage around gasket (704129).
4. Remove button head cap screw (402482) and stat-o-seal (S572) from head cylinder assy (743108). Install air bleeder assy
(704153) and connect tool to air line, cycle ten to twenty times to fully circulate oil through hydraulic system.
5.
DISCONNECT AIR FROM TOOL
. Remove air bleeder assy (704153), install button head cap screw (402482) and stat-o-seal (S572)
on head cylinder assy (743108) and torque to 40 inch lbs.
6. Connect air supply. Cycle tool ten times and check stroke of .900" (22.86mm)
min. (see diagram below). We recommend using a
pair of dial calipers. With the air actuator assy (704130) released, check dimension (A). With the air actuator (704130) depressed
check dimension (B). If stroke is not consistent within 1/64" (.0156) repeat bleeding steps 4-6.
TROUBLESHOOTING
Providing all maintenance conditions have been met, follow this systematic approach to diagnosis.
1. MORE THAN ONE PULL IS REQUIRED TO BREAK RIVET.
a) Tool needs to be bled. (See filling and bleeding instructions.)
b) Spring has fatigued, replace.
c) Jaws are stripped or packed with chips. Clean or replace.
2. SLOW OR PARTIAL OPERATION WHEN THE AIR ACTUATOR ASSY IS DEPRESSED
a) Polyseal (A-1135) and O’Rings (400792) on piston (743407) could be worn or damaged. Replace.
b) Back-up ring (S908) and O’Ring (A-201) on piston rod assy (744136) could be worn or damaged. Replace.
c) Muffler (744143) or filter inside valve spool assy (743142) may be plugged with dirt. Clean thoroughly and back-blow with
compressed air.
d) Hole in metering screw in valve spool assy (743142) may be blocked or damaged. Hole diameter should be .028". Clear
and size or replace.
3. NO OPERATION WHEN AIR ACTUATOR ASSY IS DEPRESSED
a) Tool seized due to mechanical failure or damaged parts.
4. OIL LEAKAGE
a)
DO NOT
OPERATE WITH OIL LEAKING FROM TOOL. HIGH PRESSURE OIL MAY CAUSE SEVERE PERSONAL INJURY.
b) Any oil leaking externally should be traced to its source. An o'ring or seal that leaks should be replaced.
5. AIR BYPASS FROM VALVE HOUSING
a) If the spring (744144) breaks or dislodges, air will flow freely through the muffler (744143). Replace or reset. Valve spring
installation tool (744151) is recommended.
b) Check o'rings on valve sleeve (743144), valve spool assy (743142), and valve plug (744142). If worn or damaged, replace.
Valve sleeve removal tool (744152) is recommended.
6. FASTENER STEM JAMMED IN NOSE ASSEMBLY
a) Nose assembly components require service.
DISCONNECT AIR FROM TOOL
, remove the nose from the tool and
disassemble. Replace worn or broken parts. Clean the surface the jaws ride on.
b) Stems lodged side by side in the follower. Disassemble, remove stems, and reassemble.
c) Incorrect follower.
(A)
1.126 (28.6mm)
(B)
.226 (5.7mm)
