7
Figure 8
3
Using a 5/16" punch and a pipe wrench, detach
the Upper Rod [48] from the Lower Rod [49]. Set
all parts aside.
Figure 7
4
Place a 5/16" punch in a bench vise. Slide the
Lower Rod [49] onto the punch. Separate Primer
Rod [54] from High Pressure Piston [55] with a 5/16"
punch and a 3/8" spinner wrench. Separate High
Pressure piston [55] from Piston Nut [51] with two 3/8"
spinner wrenches. Separate Piston Nut [51] from Lower
Rod [49] with 3/8" spinner wrench. Set all parts aside
from figure 7 as a group.
Figure 6
5
Clamp the Seal Adapter [39] on the flats in a bench
vise. Using an adjustable wrench, remove the Port
Extension [47]. Using a pipe wrench, remove the Fluid
Adapter [38]. With an adjustable wrench, unscrew Seal
Carrier [40] from Seal Adapter [39]. Pull Upper Rod
[48] out of Seal Adapter [39]. Slide Rod Guide [42],
Seal [43], and Seal Retainer [41] off of Upper Rod [48].
Set all parts aside. Disassembly of the Pump Lower
is now complete.
Lower Pump Assembly Procedure:
Figure 6
1
Collect the parts group shown in figure 6. Substi
-
tute rebuild kit parts in place of old items where
applicable. Clamp the Seal Adapter [39] on the flats in
a bench vise. Apply a film of grease to the o.d. of the
Upper Rod [48]. Install the Seal Retainer [41], Seal [43],
and Rod Guide [42] onto the Upper Rod [48]. Insert
the Upper Rod [48] into the Seal Adapter [39]. Secure
with Seal Carrier [40].
2
Attach Fluid Adapter [38]. Re-install Port Exten-
sion [47]. Set this subassembly aside.
Figure 7
3
Collect the parts group shown in figure 7.
Place a
5/16" punch in a bench vise. Slide the Lower Rod
[49] onto the punch. Attach Piston Nut [51] with Lower
Rod [49] with a 5/16" punch and a 3/8" spinner wrench.
Connect High Pressure piston [55] to Piston Nut [51]
with two 3/8" spinner wrenches. Connect Piston Nut
[51] to Lower Rod [49] with 3/8" spinner wrench. Set
this subassembly aside.
Figure 8
3
Collect the parts group shown in figure 8. Clamp
Fluid Adapter [38] in the bench vise. Attach Upper
Rod [48] to Lower Rod [49].
Figure 9
4
Substitute rebuild kit parts in place of old items
where applicable. With the Fluid Adapter [38] still
clamped in the bench vise, install the Upper Tube [44]
using a strap wrench. Apply a film of grease to the o.d.
of the Lower Rod [49] and slide Primer Valve [60] onto
Lower Rod [49]. Use care to avoid scarring the surface
finish on the o.d. of the Lower Rod.
Figure 10
5
With the Fluid Adapter [38] still clamped in the
bench vise, install Primer Cylinder [46] using a
strap wrench. Insert Piston [58] and secure with Nut
[59]. Lower Pump Assembly is now complete.
Air Motor Assembly Procedure:
Figure 2
1
Collect the parts group shown in figure 2.
Substitute rebuild kit parts in place of old items
where applicable. Install the Valve Bar [21] on the
mating diameter of the Detent Spool [20]. Clamp the
5/8" Jam Nut [15] in a bench vise on the flats of the
Nut and apply Loctite 638 thread lock to the internal
threads of the Jam Nut [15]. Then, Using an adjustable
open-end wrench, install and tighten the Detent Spool
[20]. Apply 85 in-lb torque.
2
Install the Exhaust Valve Stems [23] into the
Valve Bar [21]. Apply Loctite 638 thread lock to
the internal threads of the 5/16" Jam Nuts [25] and
install on the stems [23] and tighten to 70 in-lbs using
two open-end wrenches. It will be necessary to secure
the hex cap of the Valve Stem [23] with an open end
wrench while securing the first nut. Then install the
O-Ring Seals [24] into the gland of the two Valve
Stems [23].
Figure 3
3
Secure the Rod Head [33] in a bench vise,
clamping the part across the flats. Apply Loctite
263 to the internal threads. Install the Trip Rod [32]
and tighten to 40 in-lb torque. Use vise grips, applied
near the Rod Head, to turn the Trip Rod.
4
Install the following items onto the Trip Rod [32]
in the sequence and orientation shown in figure
3: Spring Retainer [14, qty=3], Trip Spring [15, qty=2],
assembled parts from stage 1, figure 2.
