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11. Remove the stop plug (43) from the upper housing
(40). Pull the upper housing 2 to 3 inches off the
cylinder (39). Rock the housing to work it free. Do not
remove the cylinder from the lower housing (41).
12. Hold the trip rod (36) steady with an adjustable
wrench on the flats of the rod, and remove the top hex
nut (20) from the trip rod.
13. Lift the upper housing assembly (40) with the spool
guides (34) and springs (38) still inside.
NOTE: If you are not using the repair kit, inspect the trip
rod above the shoulder for scoring or damage.
There must be no reduction in rod diameter. If
there is, replace the rod.
14. Pull the trip rod (36) and piston (49) from the lower
housing (41) and cylinder (39). Place the flats of the
piston in a vise. Use a hammer and punch to remove
the retainer (32). Remove the trip rod from the piston.
15. Remove the trip rod locknut (9) and piston stop (33).
If the piston is being replaced, remove and save the
compression spring (55) and the o–ring (26). New
compression rings (19) are supplied with the kit.
CAUTION
Use care when removing the piston from the cylinder
to avoid scratching the cylinder wall or the piston.
16. Remove the cylinder (39) and lower housing (41).
Remove the seals (23) from the bottom of the lower
housing.
Reassembly
1. Lubricate the seals (23**) with light oil. Install in the
lower housing (41) with lips facing top of motor .
Install the o–ring (12**) on the lower housing. Install
the lower housing, making sure it seats properly.
Install the o–rings (13**) on the cylinder (39), and
install the cylinder on the lower housing.
2. Install the compression spring (55) inside the piston
(49). The
compression rings (19**) should be
positioned with the joints 180 opposed.
3. Install the piston stop (33**) and locknut (9) on the trip
rod (36**). Slide the trip rod into the piston (49) and
spring (55). Apply low strength sealant such as
Loctite TL–222 to the retainer threads (32). With the
piston flats in a vise, screw the retainer all the way
into the piston.
CAUTION
Screwing the retainer (32) all the way into the piston
(49) is essential to prevent the retainer from backing
out during operation and damaging the motor.
4. Using a hose clamp to compress the piston rings
(19**), install the trip rod and piston in the cylinder
(39) and lower housing (41) until the tops of the
piston and cylinder are flush.
5. Clamp the trip rod flats with a wrench, and then install
the upper housing (40), so the tube fittings align with
those on the lower housing. The trip rod will protrude.
6. Slide the lower trip rod guide (34**) and spring (38**)
onto the trip rod. Install the spool (37**) with the
detent at the top. Install the top spring (38**) and
guide (34**) on the trip rod. Hold the flats of the trip
rod with an adjustable wrench and install the top hex
nut (20). Slide assembly into upper housing (40).
7. Place the o–ring (11**) on the stop plug (43**), then
place the plug on the spool (37**). Install the end cap
(44), using low strength sealant on the screws (8).
Install the tie rods (35) and washers (1).
CAUTION
To prevent damage to the spool (37) and upper
housing (40), be sure the end cap (44) and bearing
and guide (51) are installed before installing the
detent assemblies. See Step 8.
8. With the motor on its side, install the detent
assemblies:
ball (7), guide (27 – with concave
surface toward ball ), spring (29**), gasket (25**) and
retaining plug (28**). Repeat for the other detent
assembly.
9. Install the hydraulic tube (48) and tighten the
compression nuts to 40–60 ft–lb (54–82 N.m).
10. Torque the crown nuts (22) and tie rods (35) to 70–80
ft–lb (95–108 N.m).
11. Apply low strength sealant to the lower threads of the
tie rods (35) and torque the four tie rods locknuts (3)
to 20–30 ft–lb (27–41 N.m).
12. Be sure the o–ring (26) is in place in the groove on the
bottom half of the piston (49). Install the drip cover
(31) and screw (6) on the bottom of the piston (49).
Install the drip pan (5) and screws (4), making sure
the drain adapter aligns with the drain port in the base
(42).
13. Connect the pump and motor, and all fluid lines.
Install in your system. Reconnect the ground wire.
PARTS LIST
Repair Kit 221–181
Includes items listed below
Ref
No.
Part No.
Description
11
104–093
O–ring
12
104–280
O–ring
13
104–095
O–ring
19
104–103
Ring, piston, compression
23
104–203
Seal, v–block
25
150–111
Gasket
28
167–431
Plug
29
108–522
Spring
33
181–243
Stop
34
183–659
Guide
36
171–407
Rod
37
183–658
Spool
38
171–411
Spring
43
171–416
Plug
Qty
1
1
2
2
2
2
2
2
1
2
1
1
2
1
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