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WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Before You Start
To reduce downtime, be sure you have all neces-
sary repair parts available. Recommended "tool
box" spare parts are listed in the parts list with an
asterisk, for example (130*).
An air motor repair kit, part no. 206–728, is avail-
able. If you have a repair kit, use all the new parts
for the best results.
Parts included in the air motor repair kit are marked
with a dagger, for example (113†).
To avoid damaging the surfaces of some parts,
padded pliers are essential. Part No. 207–579
Padded Pliers accessory is available.
Whenever you replace the packings, also replace
the glands and bearing.
When cleaning parts, use a compatible solvent.
Inspect all parts for wear and damage and replace
as necessary.
Use light, water-proof grease whenever grease is
mentioned.
Air Motor and Throat
1. Flush the pump and Relieve the Pressure.
2. Disconnect all air and fluid hoses. Remove the
pump from its mounting and clamp the air motor in
a vise.
3. Use a pipe wrench on the knurled part of the riser
tube (160 or 163) to screw it out of the air motor
base (104). Pull the connecting rod (159 or 162)
down as far as it will go. Use a hammer and punch
to remove the pin (146) from the piston rod (128).
Screw the connecting rod out of the piston rod.
4. Manually push on the piston rod to move the
piston (118) up as far as it will go. Unscrew the
cylinder cap nut (141 or 142). Pull the nut up. Grip
the trip rod (103) with padded pliers and screw the
nut off of the rod.
Service
Do not damage the plated surface of the trip rod. A
padded pliers is available as an accessory. Damage
to the surface of the trip rod can cause poor air
motor operation.
To avoid damaging the highly polished cylinder (117)
wall, always lift the cylinder straight up off of the
piston. Never tilt the cylinder as it is being removed.
5. Remove the six screws (107) holding the
cylinder (117) to the base. Carefully pull the cylin-
der straight up off of the piston (118).
To reduce the risk of pinching or amputating your
fingers, always keep fingers clear of the toggle
assemblies (F). See Fig. 2.
6. Use a screwdriver to push down on the trip rod
yoke (109) and snap the toggles down. Remove
the lockwires (120†) from the adjusting nuts (116†)
of the transfer valves. Screw the top nuts off.
Screw the stems (115†) out of the
grommets (113†) and bottom nuts. Take the valve
poppets (114†) off the stems and squeeze them
firmly to check for cracks.
7. Grip the pivot pins (111) with a pliers. See Fig. 2.
Compress the springs (112) up away from the
piston lugs, and remove the parts. Check that the
valve actuator (121) is supported by the spring
clips (119), but slides easily into them. Remove the
trip rod yoke, actuator, and trip rod (103) check the
exhaust valve poppets (122†) for cracks.
Note: To remove the exhaust valve poppets (122),
stretch them out and cut with a sharp knife.
8. Remove one of the motor plates (127 or 135). Pull
the piston (118) up out of the base (104). Remove
the throat packing nut (132) and take out the flat
packing (130), back-up washer (129),
bearing (139), packings (137) and gland (138).
9. Clean all parts carefully in a compatible solvent,
and inspect for wear or damage. Replace parts as
necessary. Check the polished surfaces of the
piston (118), piston rod (128), and cylinder (117)
wall for scratches or wear. A scored rod will cause
premature packing wear and leaking.
CAUTION
WARNING
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Troubleshooting
