Gage Bilt GB745/206-500SH, Instructions Manual

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GB745/206 - 500SH INSTALLATION TOOL S/N 1004 AND ABOVE
PLEASE CONTACT GAGE BILT FOR ALL OTHER SERIAL NUMBERS.
Disconnect hydraulic hoses (A - 1437) and tubing (703592) from manifold - handle (745303 - 1) and drain hoses. Push piston assembly
(206129) back to rear of the cylinder machined (204300 - 4) to empty all oil from the tool. Push piston assembly (206129) to the front of
the cylinder machined (204300 - 4).
Unscrew socket head cap screw (206118) from retaining ring (206117). Use a spanner wrench to remove retaining ring. Push piston
assembly (206129) back until cylinder machined cap assembly (206115) falls out of cylinder machined (204300 - 4). Push piston
assembly (206129) out the rear of the cylinder machined (204300 - 4). Using a small blunt object, remove o'rings and back - up rings
from components.
Clean parts mineral spirits or other o'ring compatible solvent being sure to clean o'ring grooves. Inspect components for scoring,
excessive wear or damage.
Reassembly sequence is opposite of disassembly. Coat hose fitting threads with a non - hardening Teflon® thread compound such as
Slic - tite® (GAGE BILT part no. 403237).
WARNING :
Disconnect tool from its air source before disassembly.
OVERHAUL
HEAD
AIR VALVE
HANDLE
To inspect air cylinder bore, remove base cover (744124). Any further disassembly will require removal of the manifold - handle (745303 - 1).
For complete disassembly.
1. Remove base cover (744124).
2. Holding tool upright, remove four button - head cap screws (A - 928). Lift manifold - handle (745303 - 1) from handle assembly (744129)
and set aside o'ring (S832) and gasket (745124).
3 Empty all hydraulic oil into an approved container and dispose of in accordance with the material safety datasheet.
4 Place T - Handle wrench (A - 1395) down into top of power cylinder (745345) and into the hex of piston rod assembly (745347). While
holding the T - Handle wrench (A - 1395), remove flexlock nut (400559) using a 7/16" socket wrench or an adjustable wrench. Still
holding T - Handle wrench (A - 1395), remove air piston assembly (744121) using power cylinder tool assembly (704151).
5 When air piston assembly (744121) is completely free from piston rod assembly (745347), insert threaded end of power cylinder tool
assembly (704151) into bottom of air cylinder and remove air piston assembly (744121).
6 After removal of air piston assembly (744121), slide piston rod assembly (745347) back up to the end of its travel. Using packing plug
wrench assembly(704150) remove packing plug (744118).
7 With packing plug (744118) removed, power cylinder (745345) can be removed by pushing on power cylinder tool assembly (704151)
when inserted into top of power cylinder (745345).
To reassemble the handle assembly (744129).
1. Reverse the above procedure, being certain that all o'rings are properly lubricated before installation. Torque packing plug (744118)
to 45 foot lbs. (61 Nm).
2. Attach the seal guide (704152) to the piston rod assembly (745347) and tap the piston rod assembly (745347) through the packing plug
(744118).
3. Attach air piston assembly (744121) and flexlock nut (400559). Torque flexlock nut to 40 inch lbs. (4.52 Nm).
4. Attach air piston assembly (744121) to piston rod assembly (745347).
5. With the piston rod in the down position, fill oil passage on top of handle assembly (744129) with automatic transmission oil, Dexron® III or
equivalent. When looking at top of handle assembly (744129) the oil passage is the hole that has a counterbore for (S832) o'ring.
6. Replace gasket (745124) and o'ring (S832), just prior to re - attaching cylinder machined (204300 - 4). Torque all screws to manual
specifications. (See Filling & Bleeding procedures pgs. 11 - 12) & (See torque specs. pg. 10).
1. Remove pin (744149) and muffler (744143).
2. Insert valve extractor (S1178) into end of valve plug (744142) and pull it out.
3. Using the same procedure, pull out valve spool assembly (743142).
4. 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. Valve spring installation tool (744251) will facilitate the proper installation of the spring (744144).
5. Valve sleeve (743144) can be pulled out using valve sleeve removal tool (744152).