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6.
Grasp the Hammer Frame (34) and carefully lift off
entire impact mechanism making certain not to drop
the two Hammer Pins (36). If it is necessary to disas-
semble the impact mechanism, refer to Disassembly of
the Impact Mechanism. If it is unnecessary to disassem-
ble the impact mechanism, set it aside intact.
7.
Remove the Rear Hammer Frame Washer (33).
Disassembly of the Impact Mechanism
1.
Set the mechanism, driver end up, on the workbench.
Note the twin Hammers within the Hammer Frame. These
are identical but must be placed in the Hammer Frame in a
particular relationship. Using a felt tipped pen, mark the top
Hammer "T "and the bottom Hammer "B " with the arrows
pointing upward. Mark both Hammers on the same end.
2.
With the mechanism sitting upright on the workbench,
slowly rotate the Anvil in a clockwise direction until it
comes up solid.
If you continue to rotate the Anvil, it will cam the Hammers
out of engagement. Do not do this; merely rotate the Anvil
until it comes up solid.
3.
Hold the Hammer Frame firmly and, without disturb-
ing the Hammers, gently lift the Anvil, simultaneously
rotating it clockwise about 1/8 of a turn, from Hammer
Frame.
4.
With Anvil removed, lift out the two Hammer Pins.
The twin Hammers are now free to slide from the Hammer
Frame. Be careful not to drop them.
Disassembly of the Reverse Valve
1.
Using a Torx* No. 27 drive wrench or bit, remove the
four Backcap Bolts (14)
2.
Lift the Backcap off of the rear of the Housing.
3.
Discard the Backcap Gasket (15) and replace it with a
new one when assembling the tool.
4.
Use a hooked tool to remove the Reverse Valve (32)
from the reverse valve bushing. Set the Reverse Valve
aside on a clean bench.
5.
Remove and discard the Reverse Valve O-ring (31).
Replace it with a new one when assembling Reverse
Valve.
6.
Use a flat, thin blade screwdriver to remove the
Reverse Lever Retaining Ring (19) and Reverse Lever
Spring (20) from the Reverse Lever (18).
7.
Remove the Reverse Lever from the Backcap.
MAINTENANCE (Continued)
Disassembly of the Motor
Disassembly of the Throttle Mechanism
General Instructions
Assembly of the Throttle Mechansism
29
1.
Using a Torx* No. 27 drive wrench or bit, remove the
four Backcap Bolts.
2.
Remove the Backcap, Motor Clamp Washer (21) and
Backcap Gasket from from the Housing and set them
aside on a clean bench. Discard the Backcap Gasket
and replace it with a new on when assembling the tool.
3.
Lift the Housing from the Hammer Case. Place one
hand over the rear of the Housing and turn the Hous-
ing over so that the assembled motor can slide and be
guide out of the Housing.
4.
Place the assembled motor on a clean bench with the
rotor spline facing upward.
5.
Remove the Front End Plate (29) and Cylinder (27).
6.
Remove the Rotor (25) from Rear End Plate (23).
7.
Remove the Vanes from the Rotor.
8.
Inspect all motor parts including the Front Rotor Bear-
ing (30) and Rear Rotor Bearing (22) and replace all
worn or damaged parts.
1.
Unscrew and remove the Air Inlet Bushing (18).
2.
Remove the Screen (7), Throttle Valve Spring (6) and
Throttle Valve (5).
3.
If the Throttle Valve Seat (2) requires replacement,
insert a hooked tool through the center of the Valve
Seat. Catching the backside of the Seat with the hook,
pull the Seat from the Housing.
4.
Withdraw the Trigger Assembly (3) from Housing.
5.
Remove the Retaining Ring (11), Exhaust Deflector
(12) and Muffler Element (10) from the Housing.
ASSEMBLY
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 thor-
oughly into every open bearing before installation.
1.
Install a new Throttle Valve Seat (2) by pushing it into
position in the Housing (1) with a 13/16" dowel.
Form P7715 Edition 1
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