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4. Use a hooked tool to remove the Reverse Valve (10) from the
reverse valve bushing. Set the Reverse Valve aside on a clean
bench.
5. Remove and discard the Reverse Valve O-ring (6).
6. Replace it with a new one when assembling the Reverse Valve.
7. Use a flat, thin blade screwdriver to remove the Reverse Lever
Retaining Ring (9) and Reverse Lever Spring (7) from the Reverse
Lever (8).
8. Remove the Reverse Lever from the Backcap.
Disassembly of the Motor
1. Remove the four Handle Bolts (2).
2. Remove the Handle, Motor Clamp Washer (20) and Handle Gasket
(19) from the Housing and set them aside on a clean bench.
Discard the Handle Gasket and replace it with a new one when
assembling the tool.
3. Lift the Housing from the Hammer Case (43). Place one hand over
the rear of the Housing and turn the Housing over so that the
assembled motor can slide and be guide out of the Housing.
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 or 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.
6. Check every bearing for roughness. Sealed or shielded bearings
should never be cleaned. Work grease thoroughly into every
open bearing before installation.
Assembly of the Throttle Mechanisms
1. Coat the Trigger Plunger (11) with oil and insert it into the hole in
the Handle (1).
2. Install a new Throttle Valve Seat (12) in the Throttle Valve (13) and
insert it into Handle, large end first.
3. Install the Throttle Valve Spring (14), small end first, then Screen
(15). Replace Inlet O-ring (17). Coat new O-ring with O-ring
lubricant and install it in the Inlet.
4. Screw Inlet into Handle until snug and then tighten to 30-35 ft. lb.
(41-47 Nm) torque.
Assembly of the Motor
1. Pack the Front Rotor Bearing (29) and Rear Rotor Bearing (21)
with the recommended grease. Install the Front Rotor Bearing in
the Front End Plate (28) and the Rear Rotor Bearing in the Rear
End Plate (22).
2. Slide the assembled Rear End Plate and Rear Rotor Bearing on the
hub of the Rotor (24).
3. Set the assembled Rear End Plate and Rotor on a clean surface
with the spline of the Rotor pointing upward.
4. Insert the Vanes (25) in the vane slots on the Rotor.
5. Install the Front and Rear Cylinder Dowels (27) in the Cylinder
(26).
6. Slide the Cylinder over the Rotor and Vanes making sure that the
Rear Cylinder Dowel enters the notch in the outside diameter of
the Rear End Plate.
For Series 2925RBTi: Assemble Cylinder with exhaust ports to
LEFT of top dead center (11 o'clock position). See Dwg. TPD2022.
04584355_ed3
4. Place the assembled motor on a clean bench with the rotor spline
facing upward.
5. Remove the Front End Plate (28) and Cylinder (26).
6. Remove the Rotor (24) from Rear End Plate (22).
7. Remove the Vanes from the Rotor.
8. Inspect all motor parts including the Front Rotor Bearing (29) and
Rear Rotor Bearing (21) and replace all worn or damaged parts.
Disassembly of the Throttle Mechanism
1. Unscrew and remove the Air Inlet Bushing (16).
2. Remove the Screen (15), Throttle Valve Spring (14) and Throttle
Valve (13).
3. Remove the Trigger (3) from the Handle.
4. Remove the Trigger Plunger (11) from the Handle.
(Dwg. TPD2022)
If more power is needed for forward operation than for
reverse operation, install the Cylinder with exhaust ports
to the RIGHT of top dead center (1 o'clock position).
7. Install the assembled Front End Plate and Bearing over the front,
splined end of the Rotor making sure that the front Cylinder
Dowel fits into the notch in the outside diameter of the Front End
Plate.
8. Grasp the Housing with one hand and set it upside down on its
top. With the other hand, carefully guide the motor assembly into
the Housing, making sure that the side of the motor assembly
containing the Cylinder Dowels is oriented to the top of the
Housing. Install Locating Pin (23) into Housing and End Plate. See
Dwg. TPD2023-1.
NOTICE
3
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