10
REV. 4/15
HANDLE
To inspect air cylinder bore, remove base cover (744124). Any further disassembly will require removal of the manifold-handle
(744303) first. For complete disassembly, start by removing base cover (744124). Next, holding tool upright, remove four button-head
cap screws (400062). Lift manifold-handle (744303) 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 laws and regulations applicable in
your area. Place piston rod wrench (704149) down into top of power cylinder (743131), into the hex of piston rod assy (744136). While
holding this wrench (704149), remove flexlock nut (400559) using a 7/16" socket wrench. Still holding piston rod wrench (704149),
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 (744136), tap or push on the piston rod wrench (704149) to eject air piston assy (744121) from
bottom of handle assy (744129). After removal of air piston assy (744121), slide piston rod assy (744136) back up to the end of its
travel. Using packing plug wrench (704150) remove packing plug (744118). With packing plug (744118) 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, 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 (744136) and tap the piston rod
assy (744136) 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 (744136) in the down position, fill oil passage on top of handle with automatic transmission fluid,
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 manifold-handle (744303). (See Filling & Bleeding
instructions.)
AIR VALVE
WARNING
:
Disconnect tool from its 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 sleeve 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 installation tool (744151) will facilitate the proper installation of the spring (744144), valve sleeve (743144) can be
pulled out using valve sleeve removal tool (744152).
