10
Rev. 1/14
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 ass’y (745366) from handle (744129) and set aside o'ring (S832) and gasket (745124). Empty all hydraulic fluid into an
approved container and dispose of hydraulic fluid in accordance with all environmental laws and regulations applicable in your area. Place
piston rod wrench (745155) down into top of power cylinder (745331), into slot of piston rod ass’y (745344). While holding this wrench,
remove flexlock nut (400559) using a 7/16" socket wrench. Still holding piston rod wrench (745155) remove air piston (744121) using packing
plug wrench (704150), by turning counterclockwise. When air piston ass’y (744121) is completely free from piston rod ass’y (745344), tap or
push on the piston rod wrench (745155) to eject air piston ass’y (744121) from bottom of handle (744129). After removal of air piston (744121),
slide piston rod ass’y (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, 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 ass’y (745344) and tap the piston rod ass’y (745344)
through the packing plug (744118). Attach air piston ass’y (744121) and flexlock nut (400559) torque flexlock nut (400559) to 40 inch lbs. With
the piston rod ass’y (745344) in the down position, fill oil passage on top of handle (744129) with automatic transmission fluid, Dexron III or
equivalent, when looking at top of handle (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 ass’y (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 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 valve chamber. NOTE: Valve
spring tool (744151) will facilitate the proper installation of the spring (744144), valve sleeve (743144) can be pulled out using valve sleeve
removal tool (744152).
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
704130
AIR ACTUATOR ASS'Y
745124 - GASKET
S832 - O'RING
402479 - BUTTON
HEAD CAP SCREW (4)
A-249 - SWIVEL
403805 - O'RING
S908 - BACK-UP RING
745331 - POWER
CYLINDER
403805 - O'RING
S892 - O'RING
A-201 - O'RING
S908 - BACK-UP RING
745344
PISTON ROD ASSEMBLY
(INCLUDES S908 AND A-201)
