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Disconnect tool from its air source before disassembly.
1.
Remove nose assembly and adapter from tool before attempting disassembly of head assembly.
2.
Remove end cap (735117).
3.
Push against threaded end of piston (735107) to slide it out of head cylinder (735098). Be careful not to damage threads or cause
burrs on polished piston (735107) surface.
The re-assembly sequence is the opposite of disassembly. (See Filling and Bleeding procedures on pgs. 11-12). Apply Loctite® #242
and torque the button head cap screws (A-928) uniformly to 40 inch lbs. (4.52 Nm) to prevent leakage around the gasket (704129).
To inspect air cylinder bore, remove base cover (704125) and o'ring (S725). Any further disassembly will require removal of the head
cylinder (735098) first.
For complete disassembly.
1.
Remove base cover (704125) and o'ring (S725).
2.
Holding tool upright, remove four button-head cap screws (A-928) and lift head cylinder (735098) from handle assembly (722132)
and set aside o'ring (S832) and gasket (704129).
3.
Empty all hydraulic oil into an approved container and dispose of in accordance with the material safety datasheet.
4.
Place T-handle wrench (A-1395) down into top of power cylinder (731237) and into the hex of piston rod assembly (731333). While
holding the T-handle wrench (A-1395), remove flexlock nut (400559) using a 7/16" socket wrench or an adjustable wrench. Still
holding T-handle wrench (A-1395), remove air piston assembly (704121) using packing plug wrench assembly (704150), by turning
counterclockwise.
5.
When air piston assembly (704121) is completely freed from piston rod assembly (731333), tap or push on the T-handle wrench (A-1395)
to eject air piston assembly (704121) from bottom of handle assembly (722132).
6.
After removal of air piston assembly (704121), slide piston rod assembly (731333) back up to the end of its travel. Using packing
plug wrench assembly (704150), remove packing plug (704118).
7.
With packing plug (704118) removed, power cylinder (731237) can be removed by pushing on power cylinder tool assembly (704151)
when inserted into top of power cylinder (731237).
To reassemble the handle assembly (722132).
1.
Reverse the above procedure, being certain that all o'rings are properly lubricated before installation. Torque packing plug (704118)
to 45 foot lbs. (61 Nm).
2.
Attach the seal guide (704152) to the piston rod assembly (731333) and tap the piston rod assembly (731333) through the packing plug
(704118).
3.
Attach air piston assembly (704121) and flexlock nut (400559). Torque flexlock nut to 40 inch lbs. (4.52 Nm).
4.
Attach air piston assembly (704121) to piston rod assembly (731333).
5.
With the piston rod in the down position, fill oil passage on top of handle assembly (722132) with automatic transmission oil, Dexron® III
or equivalent. When looking at top of handle assembly (722132) the oil passage is the hole that has a counterbore for (S832) o'ring.
6.
Replace gasket (704129) and o'ring (S832), just prior to replacing head cylinder (735098).Torque all screws to manual specifications.
(See Filling & Bleeding procedure pgs. 11 - 12) & (See torque specs. pg. 10).
1.
Remove pin (704244) and muffler (704146).
2.
Insert valve extractor (S1178) into end of valve plug (704145) and pull it out.
3.
Using the same procedure, pull out valve spool assembly (703142).
4.
Use needle nose pliers to grasp end of spring (704141), turning clockwise and pulling to dislodge from groove in casting. Valve
spring installation tool assembly (704262) will facilitate the proper installation of the spring (704141).
5.
Valve sleeve (703139) can be pulled out using valve sleeve removal tool assembly (704163).
GB735 INSTALLATION TOOL
DISASSEMBLY
HEAD
HANDLE
AIR VALVE
16
REV. 12/22