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HANDLE

To inspect air cylinder bore, remove base cover (744124) and o'ring (S12). Any further disassembly will require removal of the head

assembly first. For complete disassembly, start by removing parts (744124) and (S12). Next, holding tool upright, remove four button

-head cap screws (402479). Lift head assembly from handle (744129) and set aside o'ring (S832) and gasket (704129). Empty all

hydraulic fluid into a container. Place piston rod wrench (704149) down into top of power cylinder, into the hex of piston rod assy.

(744136). While holding this wrench, remove flexlock nut (400559) using a 7/16" socket wrench. Still holding piston rod wrench,

remove air piston (744121) using packing plug wrench (704150), by turning counterclockwise. When air piston is completely freed

from piston rod, tap or push on the piston rod wrench to eject air piston from bottom of handle. After removal of air piston, slide

piston rod ass'y (744136) back up to the end of its travel. Using packing plug wrench (704150) remove packing plug (744118). With

packing plug removed, power cylinder (743131) can be removed by pushing on power cylinder tool (704151) when inserted into top of

power cylinder.

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 (744136) and tap the piston rod

through the packing plug (744118). Attach air piston (744121) and flexlock nut (400559) to piston rod ass'y (744136) torque flexlock

nut to 40 inch lbs. With the piston rod in the down position, fill oil passage on top of handle with automatic transmission fluid,

Dexron III or equivalent, when looking at top of handle the oil passage is the hole that has a counterbore for S832 o'ring. Replace

gasket (704129) and o'ring (S832), just prior to replacing head assembly. (See Filling & Bleeding instructions.)

AIR VALVE

WARNING:

DISCONNECT TOOL FROM ITS AIR SOURCE BEFORE DISASSEMBLY.

To disassemble, first disconnect tool from its air source.

into end of valve plug (744142) and pull it out. Using the same procedure, pull out spool (743142). NOTE: It should never be

necessary to remove valve sleeve (743144) unless the ports in the sleeve 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. NOTE:

744151 valve spring tool will facilitate the proper installation of the spring (744144), valve sleeve (743144) can be pulled out using

valve sleeve removal tool 744152.

S832 - O'RING

704129 - GASKET

704130 - TRIGGER

ASSEMBLY

744129 - HANDLE

S885 - RETAINING RING

743131 - POWER

403805 - O'RING

S908 - BACK-UP RING

A-201 - O'RING

PISTON ROD ASSEMBLY

(INCLUDES S908 AND A-201)

400062 - SOCKET

HEAD CAP SCREW (4)

CYLINDER

S892 - O'RING

744136

Remove pin (744149) and muffler (744143). Insert valve extractor (S1178)

A-249 - SWIVEL

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

Rev. 3/13