16
Rev. 2/17
GB784
HANDLE
To inspect air cylinder bore, remove base cover (744124). Any further disassembly will require removal of the head cylinder (784221) first.
For complete disassembly.
1. Remove base cover (744124).
2. Holding tool upright, remove four button-head cap screws (402479). Lift head cylinder (784221) from handle assy (744129) and set
aside o'ring (S832) and gasket (704129).
3
Empty all hydraulic oil into an approved container and dispose of in accordance with all environmental regulations applicable to your area.
4
Place piston rod wrench assy (704149) down into top of power cylinder (743131) and into the hex of piston rod assy (744136). While hold-
ing this wrench, remove flexlock nut (400559) using a 7/16" socket wrench. Still holding piston rod wrench assy (704149), remove air piston
assy (744121) using packing plug wrench assy (704150), by turning counterclockwise.
5
When air piston assy (744121) is completely free from piston rod assy (744136), tap or push on the piston rod wrench to eject air piston
assy (744121) from bottom of handle assy (744129).
6
After removal of air piston assy (744121), slide piston rod assy (744136) back up to the end of its travel. Using packing plug wrench assy
(704150) remove packing plug (744118).
7
With packing plug (744118) removed, power cylinder (743131) can be removed by pushing on power cylinder tool assy (704151) when
inserted into top of power cylinder (743131).
To reassemble the handle assy (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.
2. Attach the seal guide (704152) to the piston rod assy (744136) and tap the piston rod assy (744136) through the packing plug (744118).
3. Attach air piston assy (744121) and flexlock nut (400559). Torque flexlock nut to 40 inch lbs.
4. Attach air piston assy (744121) to piston rod assy (744136).
5. With the piston rod 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 (S832) o'ring.
6. Replace gasket (704129) and o'ring (S832), just prior to replacing head cylinder (784221). Torque all screws to manual specifications.
(See Filling & Bleeding instructions.)
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 assy (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).
WARNING
:
Disconnect tool from its air source before disassembly.
OVERHAUL
