9
REV. 7/14
S/N: 1070 AND ABOVE
PLEASE CONTACT GAGE BILT FOR ALL OTHER SERIAL NUMBERS.
743131 - POWER
CYLINDER
403805 - O'RING
S892 - O'RING
S908 - BACK-UP RING
A-201 - O'RING
744136
PISTON ROD ASSEMBLY
(INCLUDES S908 AND A-201)
400784 - O'RING
743144 - VALVE
SLEEVE
744144 - SPRING
400779 - O'RING
743142 - VALVE SPOOL
ASSEMBLY
400785 - O'RING
744142 - VALVE PLUG
400785 - O'RING
744143 - MUFFLER
744149 - PIN
A-287 - O'RING
S115 - BACK-UP RING
A-271 - O'RING
744118 - PACKING PLUG
S115 - BACK-UP RING
A-287 - O'RING
S909 - BACK-UP RING
401462 - QUAD RING
S909 - BACK-UP RING
744121 - AIR PISTON
ASSEMBLY
400559 - FLEXLOCK NUT
S12 - O'RING
744124 - BASE COVER
744129 - HANDLE
704313 - PLUG
704129 - GASKET
S832 - O'RING
A-928 - BUTTON
HEAD CAP SCREW (4)
A-249 - SWIVEL
S885 - RETAINING RING
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 (A-928). Lift manifold-handle (744303) from handle (744129) and set aside o'ring (S832) and gasket (704129). Empty all hydrau-
lic 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 ass’y (744136). While holding
this wrench, remove flexlock nut (400559) using a 7/16" socket wrench. Still holding piston rod wrench, remove air piston ass’y
(744121) using packing plug wrench (704150), by turning counterclockwise. When air piston ass’y (744121) is completely free from
piston rod ass’y (744136), tap or push on the piston rod wrench to eject air piston ass’y (744121) from bottom of handle (744129). After
removal of air piston ass’y (744121), slide piston rod ass’y (744136) back up to the end of its travel. Using packing plug wrench
(704150) remove packing plug (744118). With packing plug 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 (744129) , reverse the above procedure, being certain that all o'rings are properly lubricated before installa-
tion. Torque packing plug (744118) to 45 foot lbs. Attach the seal guide (704152) to the piston rod ass’y (744136) and tap the piston rod
ass’y (744136) through the packing plug (744118). Attach air piston ass’y (744121) and flexlock nut (400559) torque flexlock nut to 40
inch lbs. With the piston rod ass’y (744136) in the down position, fill oil passage on top of handle (744129) with automatic transmission
oil, Dexron III or equivalent, when looking at top of handle (744129) the oil passage is the hole that has a counterbore for S832 o'ring.
Replace gasket (704129) and o'ring (S832) just prior to replacing manifold-handle (744303). Torque all screws to manual specifications.
(See Filling & Bleeding instructions.)
AIR VALVE
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 ass’y (743142). NOTE: 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.
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).
