16
REV. 5/22
GB745SHV/LB8 INSTALLATION TOOL
SERIAL # 1001 AND ABOVE
WARNING
:
Disconnect tool from its air source before disassembly.
OVERHAUL
1.
Remove nose assembly and adapter from tool before attempting disassembly of head cylinder (745366).
2.
Remove connector (745503) and pull out insert (745355) from rear of end cap (745332). (See pg. 17 for disassembly).
3.
Remove end cap (745332).
4.
Push against threaded end of piston (745310) to slide it out of head cylinder (745366). Be careful not to damage threads or cause
burrs on polished piston rod surface.
The re
-
assembly sequence is the opposite of disassembly. (See Filling and Bleeding procedures pgs. 11
-
12). Apply Loctite® #242 and
torque the button head cap screws (A
-
928) uniformly to 40 inch lbs. (4.52 Nm) to prevent leakage around the gasket (745124).
HEAD
HANDLE
To inspect air cylinder bore, remove base cover (744124). Any further disassembly will require removal of the head cylinder (745366) first.
For complete disassembly.
1.
Remove base cover (744124).
2.
Holding tool upright, remove four button
-
head cap screws (A
-
928). Lift manifold
-
handle (745303) 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 safety data sheet.
4.
Place piston rod wrench (745155) down into top of power cylinder (745331) and into the hex of piston rod assembly (745344). While
holding the piston rod wrench (745155), remove flexlock nut (400559) using a 7/16" socket wrench or an adjustable wrench. Still
holding piston rod wrench (745155), remove air piston assembly (744121) using packing plug wrench assembly (704150), by turning
counterclockwise.
5.
When air piston assembly (744121) is completely free from piston rod assembly (745344), tap or push on the piston rod wrench (745155)
to eject air piston assembly (744121) from bottom of handle assembly (744129).
6.
After removal of air piston assembly (744121), slide piston rod assembly (745344) 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 (745331) can be removed by pushing on power cylinder tool assembly (704151)
when inserted into top of power cylinder (745331).
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 (745344) and tap the piston rod assembly (745344) 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 (745344).
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 replacing head cylinder (745366). Torque all screws to manual specifications.
(See Filling and Bleeding procedures pgs. 11
-
12) & (See torque specs. pg. 10).
AIR VALVE
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).
