5
REV. 7/14
S/N: 1070 AND ABOVE
PLEASE CONTACT GAGE BILT FOR ALL OTHER SERIAL NUMBERS.
FILLING:
1. Put the piston rod wrench (704149) into the top of handle (744129), pushing down firmly until piston rod (744136) is completely in the down
position.
2. Fill oil passage and reservoir with Automatic Transmission Oil Dexron III or equivalent. The reservoir is the area surrounding the power
cylinder (743131). When looking at the top of the handle (744129) the oil passage is the hole that has a counter bore 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 (744129) keeping hydraulic
hose (A-336) towards plug (704313). Tighten button head cap screws (A-928) to 40 inch lbs.
4. Push piston (743407) full forward. Install gasket (704129), o’ ring (S832) and socket head cap screws (400061 & 400066) & torque to 40
inch lbs. on manifold-head (744306). Assemble head cylinder assembly (743116) to manifold-head (744306). Apply Loctite 242 to all cap
screws and torque screws to manual specifications..
5.
Remove pin and lever from lever assembly (724017).
Coil tool up on bench and lay manifold-handle (744303) down on side so that the
hole marked #3 is to the bottom. Rest manifold-head assy (744306) over a small bucket or can. Completely fill up fill bottle (745163).
6. Remove button head cap screw (402482) and stat-o-seal (S572) from manifold-head assy (744306). 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 (745163) use other hand to replace button head cap screw (402482) and stat-o-seal
(S572) on manifold-head assy (744306) and torque to 35-40 inch lbs. This may require two people.
8. Remove fill bottle (745163) and replace stat-o-seal (S572) and button head cap screw (402482) on manifold-handle (744303) and torque
35-40 inch lbs.
BLEEDING:
1.
Remove pin and lever from lever assembly (724017).
Stand handle (744129) on floor, stretch hose and head assembly upward and lay
flat on a table or bench. When bleeding tool always keep the head assembly higher than the handle assembly.
2. Attach air bleeder ass’y (704153) to manifold-handle (744303) hole marked #3 in an upright position.
3. Connect the tool to air supply and cycle tool 10 times holding the air actuator ass’y (724017) down for 2-3 seconds between cycles to re-
move 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 35-40 inch lbs.
5. Remove button head cap screw (402482) and stat-o-seal (S572) from manifold-head ass’y (744306) and attach air bleeder ass’y (704153)
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
35-40 inch lbs.
8. Connect air supply. Cycle tool 5-6 times and check stroke of .900 (22.86 mm) (see diagram below). We recommend using a pair of dial
calipers. With the lever ass’y released, check dimension (A). Holding lever ass’y check dimension (B). If stroke is not consistent within
1/64" (.0156) repeat bleeding steps 5-6.
(A)
1.126 (28.6mm)
(B)
.226 (5.7mm)
FILLING & BLEEDING PROCEDURE:
NOTE:
Air Bleeder Ass’y (704153) and Fill bottles (745163) are required.
NOTE:
To replace a small amount of oil follow bleeding steps 5-6.
WARNING:
DO NOT CYCLE TOOL WITHOUT AIR BLEEDER ASS’Y, OR THE BUTTON HEAD
CAP SCREW AND
STAT-O-SEAL, INSTALLED IN TOOL HEAD. SEVERE PERSONAL INJURY MAY RESULT.
CAUTION:
BEFORE FILLING HANDLE, AIR PISTON ASS’Y SHOULD BE ALL THE WAY DOWN.
CAUTION:
WHEN FORCING PISTON ROD ASSEMBLY DOWNWARD WITH HEAD CYLINDER ASSEMBLY REMOVED,
HYDRAULIC OIL WILL EJECT FORCIBLY FROM HANDLE.
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 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.wmv
