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For the 2902SB
NOTICE
The Reverse Valve Stop (30) is secured with loctite
1.
Unscrew the Reverse Valve Stop (30) from the Reverse Valve (28).
2.
Slowly rotate the Reverse Valve back and forth while withdrawing it
from the reverse bushing. Remove the Reverse Valve Seal (29) from
the Reverse Valve; and the Bushing Seal (31) from the undercut
inside the reverse valve bushing.
Disassembly of the Throttle
For Model 2902P
1.
Using a pin punch, tap out the Bushing Retaining Pin (45) from left to
right while facing the back of the tool. Remove the entire Throttle
Valve Assembly.
2.
If it is necessary to replace the Trigger (40), pull it off the Throttle
Valve (38).
3.
Remove the Large Bushing O-ring (43) and one Small Bushing O-
ring (44) from the Throttle Valve Bushing (42). Remove the other
Small Bushing
O-ring (44) seated in the recess of the handle.
4.
Using a pin Punch, tap out the Throttle Valve. Retaining Pin (41) to
release the Throttle Valve from the Throttle Valve Bushing.
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 pressing
the bearing into a bearing recess.
3.
Whenever grasping a tool or part in a vise, always use leather–
covered or copper–covered vise jaws. Take extra care with threaded
parts 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 Throttle Mechanism
For the 2902P
1.
Install a new Throttle Valve Face (39) in the annular groove at the
end of the Throttle Valve (38).
2.
Install a new large Bushing O-ring (43) and a new small Bushing O-
ring (44) into their respective grooves of the Throttle Valve Bushing
(42). Seat the other new Small Bushing O-ring (44) into the recess of
the Motor Housing.
3.
Insert the Throttle Valve into the Throttle Valve Bushing, taking care
to line up the retaining pin holes in the Throttle Valve Bushing and the
Throttle Valve. Drive the Throttle Valve Retaining Pin (41) into the
Throttle Valve Retaining Pin hole.
4.
If the Trigger (40) was removed, press it onto the end of the Throttle
Valve.
5.
Install the throttle Valve Assembly into the Housing (1), taking care to
line up the cross hole in the throttle Valve Bushing with the Retaining
Pin (45) from right to left when facing the rear of the tool. Work the
Trigger a few times to assure a good sliding fit.
6.
Install the Exhaust Silencers (10) in the Housing. Make sure the
Silencer is rolled tightly for easy installation.
7.
Install the Deflector Gasket (9) and Exhaust Deflector (8).
8.
Install the Inlet Bushing (6) and Bushing O-ring (7). Tighten the
Bushing to 20 to 25 ft-lb (27 to 34 Nm) torque.
For Model 2902SB
1.
Install a new Power Regulator Seal (24) in the groove closet to the
Knurled Knob on the Power Regulator Assembly (23).
2.
Place the Detent Spring (26) and the Detent Ball (27) in the shallow
hole in the hexagonal flange of the Swivel Inlet Body (20). Capture
the Spring/Ball combination with the Power Regulator Assembly
reinstalled in the Swivel Inlet Body.
3.
Align the groove on the end of the Power Regulator shaft with the
thru hole in the Swivel Inlet Body and insert the Regulator Retainer
(25). The Regulator will turn firmly but freely within the Body when
properly assembled.
4.
Place a new Swivel Inlet Seal (22) in each counterbore in the Swivel
Inlet (21), place the Inlet Assembly Spacer (19) on the top of the
Swivel Inlet so that it aligns with the hole in the Swivel inlet and slide
the inlet over the threaded end of the Swivel Inlet Body.
Form 04584231-Edition 1
5.
Remove the Throttle Valve Face (39) from the annular groove at the
end of the Throttle Valve.
6.
Unscrew and remove the Inlet Bushing (6).
7.
Lift off the Exhaust Deflector (8) and Deflector Gasket (9). Using an
awl, remove the Exhaust Silencer (10) from the handle.
®
For Model 2902SB
.
1.
Using a punch, carefully drive the Throttle Lever Pin (17) from the
Motor Housing and remove the Throttle Lever (16).
2.
Hold the Motor Housing firmly in a vise, taking care not to distort the
motor bore. Using a wrench on the machined flats and turning
counterclockwise, remove the Swivel Inlet Body (20).
3.
Remove the Swivel Inlet Assembly (21), Seals (22), and Inlet
Assembly Spacer (19) from the Swivel Inlet Body.
The Detent Ball (27) and Detent Spring (26) will come lose when the
Power Regulator Assembly (23) is removed from the Swivel Inlet
Body.
4.
Push the Regulator Retainer (25) through the Swivel Inlet Body and
remove the Power Regulator Assembly, Detent Ball, and Detent
Spring.
5.
Withdraw the Throttle Valve Spring (15) and Throttle Valve (!3).
Remove the Throttle Valve Face (14) from the Throttle Valve.
5.
Install a new Throttle Valve (14) in the groove on the Throttle Valve
(13) and insert the assembled Throttle Valve, stem first into the
tapped hole in the Motor Housing (1).
6.
Next, insert the Throttle Valve Spring (15) into the tapped hole in the
Housing and retain the Throttle parts with the Swivel Inlet. Thread the
Inlet into the tapped hole clockwise and tighten to 23 to 27 ft-lb
(31 to 37 Nm) torque.
7.
Align the holes in the Throttle Lever (16) with the holes in the boss on
top of the Motor Housing and press the Throttle Lever Pin (17) into
the through hole. Press the Throttle Lever several times checking
that the mechanism does not bind.
8.
If the Nameplate (46) has become disfigured, replaced it after
transferring the proper serial number.
Assembly of the Reverse Valve
For Model 2902P
1.
Install two Reverse Valve O-rings (12) in the undercut at each end of
the reverse valve bushing.
Install the Reverse Valve (11) from left to right while facing the rear
of the tool.
2.
Install the Detent Ball Spring (34) and Detent Ball (33) in the Reverse
Valve, while sliding the Reverse Valve into the reverse valve bushing,
compress the Spring and Ball until they are seated in the bushing.
3.
Insert the Knob Screw (36) through the Reverse Valve Knob (35).
Apply Loctite No.242 to the first two or three threads of the Screw
and thread the Screw into the tapped end of the Reverse Valve.
While holding the serrated end of the Reverse Valve with pliers,
tighten the Screw to 4 to 7 in lb
(0.45 to 0.80 Nm) torque.
For Model 2902SB
1.
Insert a new Bushing Seal (31) into the undercut inside the reverse
valve bushing, making certain it is firmly seated.
2.
Install a new Reverse Valve Seal (29) in the groove closest to the
hexagonal end on the Reverse Valve (28). Coat the Reverse Valve
with a small amount of the recommended oil and insert the tapered
end of the Valve into the housing bushing from left to right when
facing the rear of the tool until the tapered end of the Valve protrudes
from the right side of the Housing.
Rotate the Valve back and forth slowly, being careful not to damage
the Seals when inserting the Valve in the bushing.
NOTICE
NOTICE
CAUTION
3
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