10
Rev. 9/14
GB7045
HANDLE
To inspect air cylinder bore, remove base cover (744124). Any further disassembly will require removal of the head cylinder (745366) first. For
complete disassembly, start by removing base cover (744124). Next, holding tool upright, remove four button-head cap screws (402479). Lift
head cylinder (745366) from handle assy (744129) and set aside o'ring (S832) and gasket (745124). Empty all hydraulic oil into an approved
container and dispose of hydraulic oil in accordance with all environmental regulations applicable in your area. Place piston rod wrench
(745155) down into top of power cylinder (745331) and into slot of piston rod assy (745344). While holding this wrench, remove flexlock nut
(400559) using a 7/16" socket wrench. Still holding piston rod wrench (745155), remove air piston assy (744121) using packing plug wrench
(704150), by turning counterclockwise. When air piston assy (744121) is completely free from piston rod assy (745344), tap or push on the
piston rod wrench (745155) to eject air piston assy (744121) from bottom of handle assy (744129). After removal of air piston assy (744121),
slide piston rod assy (745344) back up to the end of its travel. Using packing plug wrench (704150) remove packing plug (744118). With
packing plug (744118) removed, power cylinder (745331) can be removed by pushing on power cylinder tool (704151) when inserted into top
of power cylinder (745331).
To reassemble the handle assy (744129), reverse the above procedure, being certain that all o'rings are properly lubricated before
installation. Torque packing plug (744118) to 45 foot lbs. Attach the seal guide (704152) to the piston rod assy (745344) and tap the piston rod
assy (745344) through the packing plug (744118). Attach air piston assy (744121) and flexlock nut (400559). Torque flexlock nut (400559) to 40
inch lbs. With the piston rod assy (745344) 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 o'ring (S832).
Replace gasket (745124) and o'ring (S832), just prior to replacing head cylinder assy (745366). (See Filling & Bleeding instructions.)
AIR VALVE
WARNING
:
Disconnect tool from its air source before disassembly.
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 assy (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 valve chamber. NOTE: Valve
spring tool (744251) will facilitate the proper installation of the spring (744144), valve sleeve (743144) can be pulled out using valve sleeve
removal tool (744152).
745331 - POWER
CYLINDER
403805 - O'RING
S892 - O'RING
A-201 - O'RING
S908 - BACK-UP RING
745344
PISTON ROD ASSY
(INCLUDES S908 AND A-201)
400784 - O'RING
743144 - VALVE
SLEEVE
744144 - SPRING
400779 - O'RING
743142 - VALVE SPOOL
ASSY
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 ASSY
400559 - FLEXLOCK NUT
S12 - O'RING
744124 - BASE COVER
744129 - HANDLE ASSY
704130
AIR ACTUATOR ASSY
745124 - GASKET
S832 - O'RING
402479 - BUTTON
HEAD CAP SCREW (4)
A-249 - SWIVEL
403805 - O'RING
S908 - BACK-UP RING
