10
REV. 2/14
HANDLE
To inspect air cylinder bore, remove base cover (704125). Any further disassembly will require removal of the manifold-handle
(744303) first. For complete disassembly, start by removing base cover (704125). Next, holding tool upright, remove four socket-
head cap screws (A-928). Lift manifold-handle (744303) from handle (704132) and set aside o'ring (S832) and gasket (704129). Emp-
ty all hydraulic fluid 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 (751131), into the hex of piston rod ass’y (704138).
While holding this wrench, remove flexlock nut (400559) using a 7/16" socket wrench. Still holding piston rod wrench, remove air
piston ass’y (704121) using packing plug wrench (704150), by turning counterclockwise. When air piston ass’y (704121) is com-
pletely free from piston rod ass’y (704138), tap or push on the piston rod wrench to eject air piston ass’y (704121) from
bottom of handle (704132). After removal of air piston ass’y (704121), slide piston rod ass’y (704138) back up to the end of its
travel. Using packing plug wrench (704150) remove packing plug (704118). With packing plug ( 704118) removed, power cylinder
(751131) can be removed by pushing on power cylinder tool (704151) when inserted into top of power cylinder (751131).
To reassemble the handle, reverse the above procedure, being certain that all o'rings are properly lubricated before installation.
Torque packing plug (704118) to 45 foot lbs. Attach the seal guide (704152) to the piston rod ass’y (704138) and tap the piston rod
ass’y (704138) through the packing plug (704118). Attach air piston ass’y (704121) and flexlock nut (400559) torque flexlock nut to
40 inch lbs. With the piston rod ass’y (704138) 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 the oil passage is the hole that has a counterbore for o'ring (S832). Re-
place gasket (704129) and o'ring (S832), just prior to replacing manifold-handle (744303). (See Filling & Bleeding instructions.)
AIR VALVE
To disassemble, first disconnect tool from its air source. Remove pin (704244) and muffler (704146). Insert valve extractor (S1178)
into end of valve plug (704145) and pull it out. Using the same procedure, pull out valve spool ass’y (703142). NOTE: It should nev-
er be necessary to remove valve sleeve (703139) unless the ports in the valve sleeve are plugged from contaminated air. If ports are
plugged, use needle nose pliers to grasp end of spring (704141), turning clockwise and pulling to dislodge from groove in casting.
NOTE: 704162 valve spring installation tool will facilitate the proper installation of the spring (704141), valve sleeve (703139) can be
pulled out using valve sleeve removal tool 704163.
703142 - VALVE SPOOL
ASSEMBLY
400781 - O'RING
703139 - VALVE SLEEVE
704141 - SPRING
400778 - O'RING
400783 - O'RING
704145 - VALVE PLUG
400783 - O'RING
704146 - MUFFLER
704244 - PIN
S730 - QUAD RING
A-287 - O'RING
S115 - BACK-UP RING
704118 - PACKING PLUG
405757 - O'RING
S115 - BACK-UP RING
A-287 - O'RING
S731 - BACK-UP RING
S731 - BACK-UP RING
704121 - AIR PISTON
ASSEMBLY
400559 - FLEXLOCK NUT
S725 - O'RING
704125 - BASE COVER
S734 - RETAINING RING
751131 - POWER CYLINDER
403805 - O'RING
401102 - BACK-UP RING
S945 - O'RING
704138
PISTON ROD ASSEMBLY
(INCLUDES 401102 & S945)
704132 - HANDLE
704313 - PLUG
704129 - GASKET
S832 - O'RING
A-249 - SWIVEL
A-928 - BUTTON
HEAD CAP SCREW (4)
