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7. To remove Cylinder (21) and Front End Plate (22), thread
four 1/4"– 20 thread socket head cap screws that are at
least 3" (75 mm) long into handle end of Housing. Grasping
Housing with installed screws downward, sharply strike heads
of Screws on a sturdy table to dislodge Cylinder. Cylinder should
drop out of Housing after a few impacts. If it does not, proceed
as follows:
The following procedure requires the use of heat. Take all
necessary precautions to prevent burns. Carefully heat alternate
sides of Housing until it is very warm. Using thick, heavy gloves
to avoid being burned, grasp Housing and repeat attempt to
dislodge Cylinder.
Assembly
General Instructions
1. Always press on the inner ring of a ball–type Bearing when
installing the Bearing on a shaft.
2. Always press on the outer ring of a ball–type Bearing when
installing the Bearing in a bearing recess.
3. Whenever grasping a tool or part in a vise, always use
copper– covered or leather–covered vise jaws. Take extra care
with threaded members and Housings.
4. Always clean every part and wipe every part with a thin film of oil
before installation.
5. Apply a film of O–Ring lubricant to all O–Rings before final
assembly.
Assembly of the Handle
1. Position Trigger (5) in Handle (1) and using an arbor press, push
Trigger Pin (6) full length into Handle so that it captures Trigger.
2. Clamp Handle in leather–covered or copper–covered vise jaws
with air inlet opening upward.
3. Coat Throttle Valve Plunger (7) with oil and insert it, rounded end
leading, into the inlet hole in Handle.
4. Install a new Throttle Valve Face (9) on Throttle Valve (8) and
insert assembly, Valve Face leading, into inlet hole in Handle.
5. Encircle cone end of Air Strainer Screen (12) with large end of
Throttle Valve Spring (10) and insert both parts, Spring leading,
into the inlet hole in Handle.
6. Install Straight Inlet (11) over Strainer Screen in Handle and
tighten Inlet between 20 and 25 ft–lb (27 and 34 Nm) torque.
7. Remove Handle from vise and test Trigger. If Trigger functions
properly, place assembled Handle aside. If it does not function
properly, disassemble Handle to determine cause of problem.
Assembly of the Motor
1. Lightly clamp Motor Housing (25) in leather–covered or
copper– covered vise jaws with handle end upward.
Excessive clamping pressure will distort the Motor Housing and
make motor installation extremely difficult. Do not insert the
hammer case end of the Motor Housing more than 1" (25 mm)
into the vise jaws.
2. Coat inside surface of Housing and outer edge of Front End
Plate (22) with a light film of oil.
3. Using a long tee hex wrench as an alignment pin, insert Front End
Plate, copper face trailing, into Motor Housing. Align dowel hole
in End Plate with dowel hole at the bottom of Motor Bore.
4. Lubricate and insert a new fiber Air Port Gasket Retainer (27) in
one of the air ports inside Motor Housing.
5. Install an Air Port Gasket (26A) in the air port against Gasket
Retainer with flat end of Gasket away from Retainer.
6. Repeat Steps 4 and 5 to install remaining Gasket and Retainer in
the other air port.
7. Coat outside of Cylinder (21) with a light film of oil and using long
tee hex wrench as an alignment pin to align the holes in Cylinder
with holes in Front End Plate and Housing, insert Cylinder into
Housing.
04584298_ed2
WARNING
NOTICE
8. Remove two Air Port Gaskets (26A) and Air Port Gasket
Retainers (27) from Housing.
Disassembly of the Handle
1. Clamp Trigger Handle Assembly in leather–covered or
copper–covered vise jaws with the Straight Inlet (11) upward.
2. Using a wrench, unscrew and remove Inlet as well as Air Strainer
Screen (12) and valve Spring (10).
3. Remove Throttle Valve Assembly (8) and Valve Plunger (7) from
Handle.
4. If Trigger (5) must be removed, use an arbor press to push Trigger
Pin (6) from the Handle and slide Trigger out of slot in Handle.
8. Coat inside of Cylinder and Rotor (19) with a light film of oil and
insert the splined hub of Rotor through Cylinder into Front End
Plate.
9. Coat each Vane (20) with a light film of oil and insert a Vane into
each slot in the Rotor. Vanes must be installed with curved edge
toward center of Rotor. Spin the Rotor to settle Vanes in position.
10. Using long tee Hex Wrench to align hole in Rear End Plate (17)
with hole in Cylinder, insert the Rear End Plate, bronze face
leading, into Motor Housing against the Cylinder. End Plate is
properly seated when large trailing face of End Plate is slightly
below face of Motor Housing.
11. Grease Rear Rotor Bearing (18) and install it in recess of Rear End
Plate.
12. Remove alignment pin from assembled motor and install Cylinder
Dowel (24). The Dowel is properly seated when end of Dowel
does not protrude above End Plate.
13. Install Motor Clamp Washer (16) against Rear End Plate so that
large outer edge of Washer contacts End Plate.
Assembly of the Reverse Valve
1. Inject a small amount of grease into hole in Motor Housing (25)
where Reverse Lock Plunger (29) will be installed. With grease to
hold them in position, install Reverse Lock Plunger Spring (30)
and Lock Plunger.
2. Install a new Reverse Valve Bushing Seal (32) in annular groove on
Reverse Valve (31).
3. Coat Reverse Valve with a light film of oil and install it in Motor
Housing with the side hole nearest to Seal pointed toward
Rotor (19).
4. Position Reverse Lever (28) on Reverse Valve and while using a
thin blade screwdriver to depress Reverse Lock Plunger, push
Lever onto Reverse Valve.
5. Place a new Handle Gasket (15) on the Motor Housing.
6. Examine Reverse Valve Seal (13) located inside Handle and if it is
nicked, deformed or worn, remove it and install a new Seal.
7. Fill rotor cavity in Handle with recommended grease and position
Handle on the Motor Housing.
8. Install four Handle Cap Screws (38) and Lock Washers (39) and
using an alternate tightening pattern, tighten Screws to between
10 and 12 ft–lb (13.5 and 16.3 Nm) torque.
9. Move Reverse Lever through the forward and reverse positions to
make certain the Lever locks in position.
10. Turn assembly in vise jaws and clamp on Handle with rotor shaft
upward.
11. Grease Front Rotor Bearing (23) and place it over rotor shaft.
12. Select a socket or piece of tubing that will fit over the outside
race of the Bearing and tap it with a Hammer to seat Bearing into
Housing.
13. Pack Bearing with additional grease and rotate Rotor Shaft. If
shaft does not rotate smoothly, rap end of rotor shaft with a soft
hammer to set motor and try to rotate shaft again.
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