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3. Insert notched foot of Throttle Lever through slotted side of
Throttle Lever Spacer so end of foot hooks over top edge of
Spacer.
4. Install a new Throttle Valve Face (57) on Throttle Valve (56).
5. Insert Throttle Valve, stem end first, into bore of Throttle Body so
stem of Throttle Valve engages notch in foot of Throttle Lever.
6. Place Throttle Valve Spring (61), small end first, against the top of
Throttle Valve.
7. Install Air Strainer Cap (65), making certain large end of Throttle
Valve Spring enters counterbore in Air Strainer Cap.
8. Stand Air Strainer Screen (66) upright inside Air Strainer Cap
and place Air Strainer Screen Support (67) on the upper end of
Screen.
9. Place Air Strainer Body (68) down over Air Strainer Screen
Support and Screen and thread it into Air Strainer Cap.
Assembly of the Gearing
1. If Internal Gear (28) was removed from Motor Housing (1), install
a new Internal Gear as follows:
a.
Note that there are two notches on diametrically opposite
sides of the Internal Gear.
b.
Engage the protruding lugs on the Housing Cover (39) with
the notches on the Internal Gear and while aligning the bolt
holes on the Housing Cover with the tapped holes in the
Motor Housing, start the Internal Gear squarely into the Motor
Housing.
c.
Remove the Housing Cover and press in the Internal Gear until
it seats on the shoulder in the Motor Housing.
2. Install Grease Guide (30), flat side first, in large bore of Gear
Frame (31).
3. Slide a Planet Gear Bearing (33) into each Planet Gear (32). Work
a little grease into the bore and between the rollers of each
Bearing.
4. Support Gear Frame on short hub end. Slide a Planet Gear
between flanges on the Gear Frame, aligning bore of Planet Gear
Bearing with shaft hole in flanges.
5. Press a Planet Gear Shaft (34), beveled end first, into shaft hole
until the full diameter of Shaft is flush with front face of flange
and so half-section of Shaft protrudes from flange. When pressing
Shaft in, it must be positioned so the lug or half-section faces the
tip end of flange.
6. Install second Planet Gear and Shaft.
7. Place Rear Gear Frame Spacer (38), flat side first, on short hub of
Gear Frame.
8. Press Rear Gear Frame Bearing (36) onto short hub of Gear Frame
until it contacts the Rear Gear Frame Spacer.
9. Place Front Gear Frame Spacer (37), large diameter first, over pilot
end of the Gear Frame so it seats against flange of Gear Frame
and between lugs on Planet Gear Shafts.
10. Press Front Gear Frame Bearing (35), shield side trailing, into
bearing recess in the Housing Cover.
11. Press Housing Cover with assembled Bearing, lug side first, onto
pilot end of the Gear Frame until Bearing seats against Front Gear
Frame Spacer.
Assembly of the Motor
1.
Place Front End Plate (26), crescent grooved side first, on splined
end of the Rotor.
2.
Press Front Rotor Bearing (25), shield side first, onto hub of Rotor
until it contacts Front End Plate.
Do not press the Bearing on far enough to bind the End Plate
against the face of the Rotor.
3. Grasp Rotor Pinion in a vise so Rotor is in a vertical position.
4. Wipe each Vane (24) with a light film of oil and place a Vane in
each slot in the Rotor.
5. Place Cylinder (18) down over Rotor and against Front End Plate.
16606048_ed1
CAUTION
Make certain the Cylinder is properly installed.
There are two 3/4" (19 mm) holes, one on each of two flats
running lengthwise of the Cylinder. One of these holes is located
midway on the Cylinder; the other hole is located relatively close
to one end of the Cylinder. When you place the Cylinder down
over the Rotor, the 3/4" (19 mm) hole nearest the end of the
Cylinder must be at the trailing end.
6. Slide Rotor Bearing Spacer (21), chamfered end first, on hub of
Rotor.
7. Place Rear End Plate (23), bearing recess trailing, on hub of Rotor.
8. Press Rear Rotor Bearing (22), shield side first, on hub of Rotor
until inner race seats against Rotor Bearing Spacer.
Assembly of the Impact Mechanism
1. Coat Friction Drive Washer (49) with a film of Ingersoll Rand
No. 100 Grease and install it in bottom of Ball Cam (46).
2. Work some Ingersoll Rand No. 100 Grease into large bore of
Arbor (47), onto ball race of Arbor and on face of flange on Arbor.
3. Coat ball race on Hammer Spring Thrust Bearing Race (43) with
Ingersoll Rand No. 100 Grease and slip Hammer Spring Thrust
Bearing Race, ball race first, over shaft of the Arbor up to arbor
flange.
4. Slip seventeen Hammer Spring Thrust Bearing Balls (44) into ball
race between the face of arbor flange and Hammer Spring Thrust
Bearing Race. Grease will help hold the balls in position.
5. Coat cam grooves on Ball Cam (46) with Ingersoll Rand No. 100
Grease and set Ball Cam, open end upward, on workbench.
6. Place Arbor with its assembled Hammer Spring Thrust Bearing
Race and Bearing Balls inside Ball Cam against the Friction Drive
Washer.
7. Place Hammer Spring (48) down over Arbor and against Hammer
Spring Thrust Bearing Race.
8. Coat cam grooves inside Hammer (42) with Ingersoll Rand
No. 100 Grease.
9. Align holes in side of Hammer with points of cam grooves on
Ball Cam and seat the Hammer, open end first, down over Arbor,
Hammer Spring and Ball Cam.
10. While holding these parts intact, place assembly on table of an
arbor press so it is supported on hammer jaws and so the Arbor is
free to move downward.
11. Press against rear face of Ball Cam until points in cam groove are
aligned with the holes in side of Hammer. Place a Cam Ball (45)
into each hole in side of Hammer until it enters cam groove on
Ball Cam.
12. Slowly ease up on handle of arbor press. Impact mechanism will
stay intact.
Assembly of the Impact Wrench
1. Thread Dead Handle (29) into dead handle boss on side of Motor
Housing (1).
2. Grasp Dead Handle in a vise so bore of Motor Housing is
horizontal or nearly horizontal.
3. Install a new Reverse Valve Seal (9) on Reverse Valve (8).
4. Slip Reverse Lever (10) on hub of Reverse Valve so knob on Lever
faces hole in side of Reverse Valve.
5. Insert Reverse Valve into bore of Reverse Valve Bushing (2) so
knob on Reverse Lever faces outside of Motor Housing.
6. Be certain both Air Port Gaskets (3) are in good condition and
are installed, large open end first, in the two air ports in bore of
Motor Housing.
7. Install the assembled motor as follows:
a.
Align dowel hole in each End Plate (23 and 26) with dowel
hole in Cylinder (18) and insert a 1/4" (6 mm) diameter rod
about 12" (305 mm) long, allowing it to protrude about 6" (150
mm) from Front End Plate.
b.
Insert protruding end of the rod into dowel hole at bottom of
motor housing bore and slide motor into Motor Housing.
NOTICE
3
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