11
REV. 3/15
GB731 S/N: 1702 AND ABOVE
PLEASE CONTACT GAGE BILT FOR ALL OTHER SERIAL NUMBERS.
AIR VALVE
WARNING
:
Disconnect tool from its air source before disassembly.
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 assy (703142). NOTE: It should never be
necessary to remove valve sleeve (703139) unless the ports in the valve sleeve (703139) are plugged from contaminated air. If ports
are plugged, use needle nose pliers to grasp end of spring (704141), turning clockwise and pull to dislodge from groove in casting.
NOTE: Valve spring (704162) tool will facilitate the proper installation of the spring (704141), valve sleeve (703139) can be pulled out
using valve sleeve removal tool (704163).
HANDLE
To inspect air cylinder bore, remove base cover (704125). Any further disassembly will require removal of the head cylinder (731298)
first. For complete disassembly, start by removing base cover (704125). Next, holding tool upright, remove four button-head cap
screws (A-928). Lift head cylinder (731298) from handle assy (722132) 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 regulations applicable in your area.
Place piston rod wrench (A-1395) down into top of power cylinder (731237) and into slot of piston rod assy. (731333). While holding
this wrench, remove flexlock nut (400559) using a 7/16" socket wrench. Still holding piston rod wrench (A-1395), remove air piston
assy (704121) using packing plug wrench (704150), by turning counterclockwise. When air piston assy (704121) is completely free
from piston rod assy (731333), tap or push on the piston rod wrench (A-1395), to eject air piston assy (704121) from bottom of handle
assy (722132). After removal of air piston assy (704121), slide piston rod assy (731333) back up to the end of its travel. Using packing
plug wrench (704150) remove packing plug (704118). With packing plug (704118) removed, power cylinder (731237) can be removed by
pushing on power cylinder tool (704151) when inserted into top of power cylinder (731237).
To reassemble the handle assy (722132), 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 assy (731333) and tap the
piston rod assy (731333) through the packing plug (704118). Attach air piston assy (704121) and flexlock nut (400559) torque flexlock
nut (400559) to 40 inch lbs. With the piston rod assy (731333) in the down position, fill oil passage on top of handle assy (722132) with
automatic transmission oil, Dexron III or equivalent, when looking at top of handle assy (722132) 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 head cylinder (731298). (See Filling &
Bleeding instructions).
