9/14
7
FILLING:
1. Remove manifold-handle (744303), o’ring (S832), button head cap screws (A-928) and gasket (704129) from handle assy (704132). Put
the piston rod wrench (704149) into the top of handle assy (704132), pushing down firmly until piston rod assy (704138) is completely
in the down position.
CAUTION:
When forcing piston rod assy (704138) downward, with head cylinder assy (703134) removed, hydraulic oil will eject forcibly from
handle assy (704132).
2. Fill oil passage and reservoir with Automatic Transmission Oil, Dexron III or equivalent. The reservoir is the area surrounding
the power cylinder (751131). When looking at the top of the handle assy (704132), the oil passage is the hole that has a counter
bore for o’ ring (S832). Do not overfill causing oil to go in air passage hole.
3. Re-install o’ ring (S832), gasket (704129), button head cap screws (A-928) and manifold-handle (744303) to handle assy (704132)
keeping hydraulic hose (A-336) towards plug (704313). Torque button head cap screws (A-928) to 40 inch lbs.
4. Push piston (703607) full forward. Install gasket (704129), o’ ring (S832) and socket head cap screws (400061 & 400066) on mani-
fold-head assy (744306). Assemble head cylinder assy (703134) to manifold-head assy (744306). Apply Loctite 242 to all cap
screws and torque socket head cap screws (400061 & 400066) to 40 inch lbs.
5.
Remove lever assy (724017) from manifold-head assy (744306).
Coil tool up on bench and lay handle assy (704132) down on
side so that the hole marked #3 on manifold-handle (744303) is to the top. Set head cylinder assy (703134) over a small bucket
or can. Completely fill up fill bottle assy (745163).
6. Remove button head cap screw (402482) and stat-o-seal (S572) from manifold-handle (744303) hole #3. Connect fill bottle assy (745163) to manifold-
handle (744303) hole marked #3. Remove button head cap screw (402482) and stat-o-seal (S572) from hole marked #4 manifold–head assy (744306).
7. In one continuous squeeze force oil into manifold-handle (744303) until oil starts to flow from bleeder hole marked #4 on manifold-
head assy (744306). While still squeezing the fill bottle assy (745163) use other hand to replace button head cap screw (402482) and
stat-o-seal (S572) on manifold-head assy (744306) and torque to 35-40 inch lbs. This may require two people.
8. Remove fill bottle assy (745163) and replace stat-o-seal (S572) and button head cap screw (402482) on manifold-handle (744303)
and torque to 35-40 inch lbs.
BLEEDING:
1.
Ensure lever assy (724017) is removed from manifold-head assy (744306).
Stand handle assy (704132) on floor, stretch hydraulic
hose (A-336) and head cylinder assy (703134) upward and lay flat on a table or bench. When bleeding tool always keep the head
cylinder assy (703134) higher than the handle assy (704132).
2. Remove button head cap screw (402482) and stat-o-seal (S572) from manifold-handle (744303). Attach air bleeder assy (704153) to mani-
fold-handle (744303) hole marked #3 in an upright position.
3. Connect the tool to air supply and cycle tool 10 times holding the air actuator assy (704130) down for 2-3 seconds between
cycles to remove any air from the tool.
4. Disconnect air supply. Remove air bleeder assy (704153) from manifold-handle (744303) and replace with button head cap screw
(402482) and stat-o-seal (S572) and torque to 35-40 inch lbs.
5. Remove button head cap screw (402482) and stat-o-seal (S572) from hole marked #4 manifold-head assy (744306) and attach air
bleeder assy (704153) in an upright position.
6. Connect air supply. Cycle tool 10 times removing any air bubbles.
7. Disconnect air supply. Remove air bleeder assy (704153) and replace button head cap screw (402482) and stat-o-seal (S572) and torque to 35-40 inch lbs.
8. Connect air supply. Cycle tool 5-6 times and check stroke of .780 (19.81mm) (see diagram below). We recommend using dial calipers.
With the air actuator assy (704130) released, check dimension (A). Holding air actuator assy (704130) check dimension (B). If
stroke is not consistent within 1/64" (.0156”) repeat bleeding steps 5-6.
9.
Re-attach lever assy (724017) to split handle manifold-head assy (744306).
.365 (9.3mm)
'A'
1.145 (29.1mm)
FILLING & BLEEDING PROCEDURE:
NOTE:
Air Bleeder Assy (704153) and Fill Bottle (745263) are required.
NOTE:
To replace a small amount of oil follow BLEEDING steps 5-6.
WARNING:
Do not cycle tool without air bleeder assy (704153), or the screw and stat-o-seal, installed in tool head. Severe personal injury could result.
CAUTION:
Before filling handle assy (704132), air piston assy (704121) should be all the way down.
CAUTION:
When forcing piston rod assy (704138) downward, with head cylinder assy (703134) removed, hydraulic oil will eject forcibly from
handle assy (704132).
CAUTION:
When bleeding tool, ensure tubing (see pg#13-14) is free from kinks or other obstructions.
CAUTION:
Use CAUTION when removing screws, air bleeder assy (704153) and fill bottle (745263). Hydraulic oil may be under pressure.
IMPORTANT:
Be sure to use thread sealant on all hydraulic fittings, Loctite® 30534 or similar Teflon® infused pipe dope is recommended.
CAUTION:
Teflon tape is an excellent thread sealer, however, if it is not properly applied, pieces of Teflon may enter the
hydraulic system and cause malfunction or damage. Use 1 1/2 wraps of tape on each thread. Cut off all loose tape ends.
Tighten until fitting feels snug and then go 1/2 to a full turn past that point.
CAUTION:
Over tightening can easily distort the threads.
* FILLING & BLEEDING VIDEO AVAILABLE AT:
www.gagebilt.com/bleeding.htm
