6
REV. 4/15
NOTE:
To retro-fit a bottle tool to a split assembly, air actuator assy (704130) is removed from handle assy (744129) and replaced
with button head cap screw (704313). The air actuator assy (704130) is then installed in split handle or adapter.
'B'
.685 (4.7mm)
'A'
.185 (4.7mm)
FILLING & BLEEDING PROCEDURE:
NOTE:
Air bleeder assy (704153) and fill bottle (745263) are required.
WARNING:
Do not cycle tool without air bleeder assy, or button head cap screw and stat-o-seal, installed in tool head.
Severe personal injury may result.
CAUTION:
Before filling handle, air piston assy should be all the way down.
CAUTION:
When forcing piston rod assy downward with head cylinder assy removed, hydraulic oil will eject forcibly from handle.
CAUTION:
Use CAUTION when removing button head cap screw (402482), hydraulic oil may be under pressure.
WARNING:
Failure to follow these instructions carefully may result in severe personal injury.
IMPORTANT:
Be sure to use thread sealant on all hydraulic fittings, Loctite® 30534 or similar Teflon® infused pipe dope is recom-
mended.
CAUTION:
Teflon tape is an excellent thread sealer, however, if it is not properly applied, pieces may enter the hydraulic
system and cause malfunction and 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
To replace a small amount of oil in the tool, attach the air bleeder assy (704153) and connect tool to air line. Cycle ten times. Discon-
nect air, remove the air bleeder assy (704153), and replace stat-o-seal (S572) and button head cap screw (402482). This will ensure
the removal of any air from the hydraulic system and its replacement with oil.
FILLING:
1. Put the piston rod wrench (704149) into the top of handle (744129), pushing down firmly until piston rod assy (744136) is
completely in the down position.
2.
Fill oil passage and reservoir with Automatic Transmission Oil Dexron III or equivalent. The reservoir is the area surrounding the
power cylinder (743131). When looking at the top of the handle assy (744129), 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. Install o’ ring (S832), gasket (704129), button head cap screws (400062) and manifold-handle (744303) to handle assy (744129)
keeping hydraulic hose (A-317) towards plug (704313). Torque button head cap screws (400062) to 40 inch lbs.
4. Push piston (752507) full forward. Install gasket (704129), o’ ring (S832) and socket head cap screws (400061) on split handle (700323). Assemble
head cylinder assy (752120) to split handle (700323). Apply Loctite 242 to all cap screws. Torque button head cap screws (400061) to 40 inch lbs.
5.
Remove pin and lever from actuator lever assy (704343).
Coil tool up on bench and lay handle assy (744129) down on side so that the
hole marked #3 is to the bottom. Rest head cylinder assy (752120) over a small bucket or can. Completely fill, fill bottle (745263).
6. Connect fill bottle (745263) to manifold-handle (744303) hole marked #2. Remove button head cap screw (402482) and
stat-o-seal (S572) from head cylinder assy (752120). Torque (402482) to 35-40 inch lbs.
(Do NOT over-tighten)
7.
In one continuous squeeze force oil into manifold-handle (744303) until oil starts to flow from bleeder hole on head cylinder assy
(752120). While still squeezing the fill bottle (745263), use other hand to replace button head cap screw (402482) and stat-o-seal (S572).
This may require two people.
8. Remove fill bottle (745263) and replace stat-o-seal (S572) and button head cap screw (402482). Torque (402482) to 35-40 inch lbs.
(Do NOT over-tighten)
BLEEDING:
1. Stand handle assy (744129) on floor, stretch hose and head assembly upward and lay flat on a table or bench. When bleeding tool
always keep the head cylinder assembly higher than the handle assembly.
6. Remove button head cap screw (402482) and stat-o-seal (S572) from manifold-handle (744303) hole marked #3 and attach air
bleeder assy (704153) to manifold-handle (744303) hole marked #3 in an upright position.
3. Connect the tool to air supply and cycle tool ten times, holding the actuator lever assy (704312) 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). Torque (402482) to 35-40 inch lbs.
(Do NOT over-tighten)
5.
Remove button head cap screw (402482) and stat-o-seal (S572) from head cylinder assy and attach air bleeder assy (704153) in an upright position.
6. Connect air supply. Cycle tool ten 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).
Torque (402482) to 35-40 inch lbs.
(Do NOT over-tighten)
8. Connect air supply. Cycle tool 5-6 times and check stroke of .500 (12.7mm) (see diagram below). We recommend using dial calipers.
With the actuator lever assy (704312) released, check dimension (A). Holding actuator lever assy (704312) check dimension (B).
Subtract dimension (A) from dimension (B). If stroke is not consistent within 1/64" (.0156) repeat bleeding steps 5-8.
