Cleco W2119 series, Operation & Service Manual, Page: 5 / 12

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should not be removed from the housing unless replace-
ment is necessary. If cylinder replacement is necessary, a 4-
5/32" O.D. bushing driver (with a suitable relief for the
alignment key, No. 867981) should be used to press the
cylinder out of the housing.
Remove the rotor bearings, No. 867995, from the bearing
plates for inspection. For better performance, it is recom-
mended that the rotor shaft seals, No. 867996, be replaced
during each repair.
NOTE: UNLESS THE "0" RINGS, NO. 844309, LOCATED
ON THE O.D. OF THE BEARING PLATE ARE SEVERELY
DAMAGED, THEY SHOULD NOT BE REMOVED. IF RE-
PLACEMENT IS NECESSARY, REPLACEMENT "0" RINGS
SHOULD BE INSTALLED WITH A FAST CURE CONTACT
ADHESIVE ("LOCTITE" 404).
For cleaning and inspection of the three (3) muffler plates,
No. 869004, unscrew the retainer screw, No. 883695.
HANDLE ASSEMBLIES
Both the inside and outside trigger handle assemblies are
disassembled using the same procedure. Unscrewing the
air inlet bushing, No. 864972, will allow the "0"ring, No.
863009, air inlet screen, No. 843656, throttle valve spring,
No. 864973, throttle valve No. 867974, throttle valve seal,
No. 867977, and throttle valve pin, No. 867982, to be
removed from the handle.
If the throttle pin bushing, No. 864975, should need replac-
ing, tap. the I.D. of the bushing with a 114"-20 thread tap.
Insert a 114-20 bolt of the appropriate length and clamp the
bolt in the vise. Drive the handle away from the vise using a
soft mallet.
If the trigger should need replacing, only the trigger pin (solid
pin), No. 832125, need be removed.
MAINTENANCE - REASSEMBLY
CLEANING AND INSPECTION
All parts should be cleaned in a solvent and inspected for
wear or damage. If rotor blades measure less than 7116 on
either end, they should be replaced. Rotor bearings should
be replaced if they feel rough after cleaning or show exces-
sive looseness.
HANDLE ASSEMBLY
When instailing the trigger use a pin slightly smaller than the
hole in the handle to locate the trigger when driving the
trigger pin, No 832125. into the handle.
If the throttle valve bushing No 864975, was removed, the
new bushing should be pressed in to a depth of 1 15/16" plus
or minus 1/64 from the bottom face of the handle.
Inspect the throttle valve seal, No, 867977, for wear or
deterioration. If replacement is necessary, the new seal
should be pushed (cupped face first) on the throttle valve,
No. 867974, from the tapered end. Inspect the "O"-ring, No.
863009, and replace if necessary. Clean the threads on the
air inlet bushing, No 864972, and apply "LOCKTITE" No. 271
to the threads.
Now install the throttle valve pin, No 867982, and throttle
valve assembly into the handle. Place the inlet air screen,
No. 843656, arid throttle valve spring, No. 864973, in the air
inlet bushing and screw the bushing into the handle. The
bushing should be torqued to 80 It lbs. minimum.
MOTOR UNIT
Insert the three (3) muffler plates. No. 869004, and install the
retaining screw, No. 883695.
During reassembly of the bearing plates, No. 867985, the
rotor shaft seals, No. 867996, should be installed with their
"lips'' facing out (visible after installation). When installing
the rotor bearings, No. 867995, press on the bearing's outer
race. Lubricate both the seals and rotor bearings with 30W
oil before assembly into the motor unit. Inspect the "O"-ring,
No. 863096, and replace if necessary. This "O"-ring is used
only on the front bearing plate (both bearing plates are
identical).
If the cylinder was removed, the new cylinder (with alignment
key, No. 867981, in place) should be pressed in from the rear
of the motor housing to a depth 5/8" from the rear face of the
housing.
Lubricate the "O"-rings on the O.D. of the rear bearing plate
assembly and press the assembly into the housing. When
installing either bearing plate assembly, be sure the "O"-
rings line up with the air ports in the housing. Invert the
housing and install the rotor with the end stamped ''REAR"
into the rear rotor bearing, No. 867995.
Insert the six (6) rotor blades, No. 867975, then lubricate the
"O''-rings on the front bearing plate assembly and press the
assembly into the housing. NOTE: Be sure '0--ring, No.
863096, is in place on the front bearing plate.
IMPACT MECHANISM
All parts should receive a thin coating of 30W oil before
assembly.
Insert the timing pin, No. 867966, into the recess located on
the small O.D. of the cam, No. 867991, and then install the
cam and pin into the rear of the hammer, No. 867969.
Install the cam roller shaft, No. 867979, in the cam shaft, No.
867973. Put the cam roller, No. 867978, on the roller shaft
and slip the butt plate, No. 869011, insulator, No. 869012,
and shock absorber, No. 867980, onto the rear of the cam
shaft. Hold the cam shaft vertically on the work bench with
the shock absorber down and tap the end of the cam shaft
with a soft mallet to seat the cam shaft in the shock absorber.
Slip the cam shaft and related components through the cam
and hammer assembly. Install the hammer spring, No.
867984 spring clip, No. 867964, and anvil pin, No. 867994,