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TROUBLE SHOOTING

Providing all maintenance conditions have been met, follow this systematic approach to diagnosis.

1. NO OPERATION WHEN TRIGGER IS DEPRESSED

a.) Check Powerunit power source.

b.) Control cord may be loose or damaged.

c.) Faulty trigger. Replace.

d.) Check hydraulic couplings; repair or replace.

2. SLOW OR PARTIAL OPERATION WHEN TRIGGER IS DEPRESSED

a.) Low hydraulic pressure. Check powerunit, adjust.

b.) Cylinder Piston Rings (8) & (9) could be worn or damaged. Replace.

c.) Excessive wear or scoring on moving parts. Check and replace faulty parts.

3. TOOL OPERATES IN REVERSE

a.) Tool stops in back position. Hydraulic hoses are reversed. Correct.

4. HYDRAULIC OIL OVERHEATS

a.) Powerunit motor rotation reversed. Electrical connections reversed. See powerunit instruction manual.

b.) Restrictions in either hydraulic lines, hoses or couplings. Check and tighten, clean or replace.

5. OIL LEAKAGE

a.) Hydraulic oil leaks from connections. Tighten threaded connections. Do not use Teflon® tape.

b.) Oil leaks from tool. Determine source of leak and replace worn or defective o'rings and back-up rings.

6. PINTAIL GROOVES STRIPPED DURING PULL STROKE

a.) Nose Assembly must be pushed onto fastener fully.

b.) Chips may have collected in the puller. Disassemble nose assembly, clean puller in mineral spirits using a sharp

pointed object.

c.) Puller may be worn or damaged. Replace.

d.) Incorrect fastener.

e.) Excessive gap between sheets. Reduce gap before attempting to install fastener.

OVERHAUL

If a tool is performing poorly or leaking badly, a complete overhaul may be necessary. Service Kit 772000 contains a

complete set of o'rings, back-up rings and screws.

Wrench 750150 (sold separately) is recommended for complete tool overhaul.

Perform overhaul in a clean, well lit area using care not to scratch or nick any smooth surface that comes in contact with

an o'ring. Use of Lubriplate® (Gage Bilt part no. 402723) or other lubricant is recommended during reassembly to prevent

tearing or distorting of o'rings.

Disconnect hydraulic hoses (24) and electrical cord (28) from powerunit. Remove couplers (25 & 26) from hoses (24) and

drain. Remove nut (1), split ring (2) and nose assembly. Using wrench (750150 sold separately) remove front gland (1).

Remove cap (17) and push piston assembly (10) rearward to expose rear piston (14) and remove. Push front piston assembly

(10) out front of cylinder (11).

To remove hoses, remove couplers (25 & 26), remove socket head cap screws (21), washers (18) and slide handle (23) off.

Clean parts in 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. Be sure relative positions of o'rings and back-up rings are as shown in

exploded view and part list. Relief valve must be installed with four flats towards the rear of the cylinder. Coat hose fitting

threads with a non-hardening teflon thread compound such as Slic-tite® (Gage Bilt part no. 403237). DO NOT USE TEFLON

TAPE. Apply hot glue to wire connections to ensure wires DO NOT contact each other or handle ass'y.