10
Rev. 2/15
HANDLE
To inspect air cylinder bore, remove base cover (744124) and o’ring (S12). Any further disassembly will require removal of the head cylinder assy
first. For complete disassembly, start by removing base cover (744124) and o’ring (S12). Next, holding tool upright, remove four button-head cap
screws (402479). Lift head assembly 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, into the hex of piston rod assy (740136). While holding this wrench, remove flexlock nut (400559) using a 7/16"
socket wrench. Still holding piston rod wrench, 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 (740136), tap or push on the piston rod wrench to eject air piston assy
(744121) from bottom of handle assy (744129). After removal of air piston assy (744121), slide piston rod assy (740136) back up to the end of its
travel. Using packing plug wrench (704150) remove packing plug (744118). With packing plug 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 (740136) and tap the piston rod assy (740136)
through the packing plug (744118). Attach air piston assy (744121) and flexlock nut (400559), torque flexlock nut to 40 inch lbs. With the piston rod
assy (740136) 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 (744103). (See Filling & Bleeding instructions.)
AIR VALVE
WARNING
:
Disconnect tool from 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).
