15
REV. 6/22
GB786/204 INSTALLATION TOOL
WARNING
:
Disconnect tool from its air source before disassembly.
OVERHAUL
HEAD
AIR VALVE
HANDLE
To inspect air cylinder bore, remove handle base (870175) . Any further disassembly will require removal of the manifold
-
handle (786303).
For complete disassembly.
1.
Remove handle base (870175).
2.
Holding tool upright, remove six socket head cap screws (400062 & 400063). Lift manifold
-
handle (786303) from handle (870149) and
set aside o'ring (404550) and head gasket (870143).
3
Empty all hydraulic oil into an approved container and dispose of in accordance with the material safety datasheet.
4
Place piston rod wrench (745155) down into top of power cylinder (786131) and into the slot of piston rod assembly (786133). While
holding the piston rod wrench (745155), remove cotter pin (401314), then slotted nut (S302) using a 7/16" socket wrench or an
adjustable wrench. Still holding piston rod wrench (745155), remove air piston (870169) using power cylinder tool assembly (704151).
5
When air piston (870169) is completely free from piston rod assembly (786133), insert threaded end of power cylinder tool assembly
(704151) into bottom of air cylinder and remove air piston (870169).
6
After removal of air piston (870169), slide piston rod assembly (786133) back up to the end of its travel. Using packing plug
wrench (756151) remove packing plug (870166).
7
With packing plug (870166) removed, power cylinder (786131) can be removed by pushing on power cylinder tool assembly (704151)
when inserted into top of power cylinder (786131).
To reassemble the handle (870149).
1.
Reverse the above procedure, being certain that all o'rings are properly lubricated before installation. Torque packing plug (870166)
to 45 foot lbs. (61 Nm).
2.
Attach the seal guide (870201) to the piston rod assembly (786133) and tap the piston rod assembly (786133) through the packing plug
(870166).
3.
Attach air piston (870169) and slotted nut (S302). Torque slotted nut (S302) to 40 inch lbs. (4.52 Nm).
4.
Attach air piston (870169) to piston rod assembly (786133). Insert cotter pin (401314).
5.
With the piston rod in the down position, fill oil passage on top of handle (870149) with automatic transmission oil, Dexron® III or
equivalent. When looking at top of handle (870149) the oil passage is the hole that has a counterbore for (404550) o'ring.
6.
Replace head gasket (870143) and o'ring (404550), just prior to replacing cylinder (204300). Torque all screws to manual specifications.
(See Filling & Bleeding procedures pgs. 11
-
12) & (See torque specs. pg. 10).
1.
Remove pin (744149) and muffler (744143).
2.
Insert valve extractor (S1178) into end of valve plug (744142) and pull it out.
3.
Using the same procedure, pull out valve spool assembly (743142).
4.
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. Valve spring installation tool (744251) will facilitate the proper installation of the spring (744144).
5.
Valve sleeve (743144) can be pulled out using valve sleeve removal tool (744152).
1.
Disconnect hydraulic hose assembly (A
-
1437) and air line (204122) from manifold
-
handle (786303) and drain hoses into a container.
2.
Push piston assembly (204203) back to rear of the cylinder (204300) to empty all oil from the tool. Push piston assembly (204203)
back to the front of the cylinder (204300).
3.
Unscrew socket head cap screw (206118) from retaining ring (206117). Use a spanner wrench to remove retaining ring (206117).
4.
Push piston assembly (204203) back until cylinder cap assembly (206115) falls out of cylinder (204300). Push piston assembly
(204203) out the rear of the cylinder (204300). Using a small blunt object, remove o'rings and back
-
up rings from components.
Clean parts mineral spirits or other o'ring compatible solvent being sure to clean o'ring grooves. Inspect components for scoring,
excessive wear or damage.
Reassembly sequence is opposite of disassembly. Coat hose fitting threads with a non
-
hardening Teflon® thread compound such as
Slic
-
tite® (GAGE BILT part no. 403237).
