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Replace Cylinder
Install Piston and Piston Rod
Seals
1. Remove adhesive sheet from pad (72) and install
outside the new cylinder (1). Lubricate the ID of the
cylinder (1), using a rag soaked in grease. See F
3, page 7.
2. Apply anaerobic thread sealant to the jam nut (73)
and piston rod threads. Torque to 203-228 N•m
(150-170 ft-lb).
3. Lubricate the seals and o-ring (7*, 8*, 11*). The bot-
tom of the bearing (6) has a narrow o-ring groove on
the outer surface. Install the o-ring (11*) in this
groove. Install the wiper (8*) in the bearing, so the
notch of the wiper faces down, out of the bearing. At
the top of the bearing, install the seal (7*) so the lips
face up, toward the cylinder (1).
4. Press the bearing assembly into the neck of the cyl-
inder (1) from the bottom until it is seated.
5. Install the bottom support bracket (35). Apply thread
sealant to the screws (14) and torque to 6–7 N•m
(55–65 in-lb).
6. If the adapter (R) was disassembled, screw the pis-
ton rod onto the adapter (R). Using adjustable
wrenches on the flats of the piston rod, torque to
318–349 N•m (234–257 ft-lb).
7. Lubricate the o-ring (9*) and install it on the piston
(5).
8. Lubricate the piston rod. Lower the piston assembly
into the cylinder (1), carefully sliding the adapter and
rod down through the bearing (6).
9. Reconnect the air motor to the displacement pump
(see your separate pump manual).
10. Lubricate the o-ring (10) and install it on the motor
cap (2). Place the motor cap on the cylinder (1) so
the push rod hole (M) is aligned with the flat surface
(F) of the cylinder. Attach the cap with the fifteen
capscrews (12), using a 17 mm socket wrench.
Torque to 39–43 N•m (29–32 ft-lb).
11. Lubricate the o-ring (11*) and install it on the under-
side of the lift ring (3). Align the lift ring with the six
inner holes in the motor cap, with the grounding lug
(49) positioned as shown. Apply thread sealant and
install the six screws (13).
8
12. Reassemble the subplate and rocker assemblies.
Install Subplate and Rocker
Assemblies
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1. Lubricate the seal (21) and insert it in the motor cap
(2) with the lips facing into the cap. Install the rod
fitting (20). Grease the end of the push rod (19) and
insert it in the fitting. Apply thread sealant and
torque the screws (42) to 2–3 N•m (20–30 in-lb).
Repeat for the bottom push rod assembly. See F
2, page 5.
2. Place the gasket (24) on the back side of the sub-
plate (23), aligning the holes in both parts. With the
air inlet port (P) facing up, install the subplate on the
cylinder (1) with the eight socket screws (41).
Torque to 10–12 N•m (90–110 in-lb).
3. Install the two liners (44) in the cavities of the
exhaust manifold (45). Attach the manifold to the
subplate with the gasket (47) and capscrew (43),
using a 17 mm box wrench. Torque to 24–27 N•m
(18–20 ft-lb).
4. Lubricate the sleeve (31) and two bearings (32) and
install them in the rocker arm (29). Position the
rocker arm between the top flanges of the subplate
(23).
5. Note that the rocker arm cover (62) has two tabs
that are off-center. Install the cover so the end with
the two tabs is toward the outside of the subplate
(see Fig. 9). Insert the stud (30) through the cover
and rocker arm, then install the nut (33). Torque to
195–205 in-lb). Replace the rocker 22–23 N•m arm
cover pad (63, see F
6. Assemble the bottom rocker assembly as explained
in steps 4 and 5. Install the bottom cover (61) and
secure to the rocker arm cover with the two screws
(13) and washers (51).
7. Install the two seals (27) and the gasket (26). See
the Detail in F
8. Install the air valve (25), using a 6 mm allen wrench
and six socket screws (28). Torque to 22–23 N•m
195–205 in-lb).
. 1, page 3).
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. 1, page 3.
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3A2715B
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