8
SERVICE
DISASSEMBLY
NOTE:
Repair Kit 223–895 is available to repair the air
motor. Parts included in the kit are marked with
an asterisk, for example (103a*). For the best re-
sults, use all the new parts in the kit.
Repair Kit 223–894 is available to repair the fluid
pump. Parts included in the kit are marked with a
double asterisk, for example (1 14**). For the
best results, use all the new parts in the kit.
1. Follow the
Pressure Relief Procedure Warning
on
page 7. Disconnect all hoses. Remove the wiper
plate (300). Remove the fluid outlet fitting (128), not-
ing its position relative to the air inlet. Remove
only
the three screws (138) and lockwashers (141) hold-
ing the pump to the mounting bracket (233). DO NOT
remove the remaining screws (138) and lockwash-
ers (141) at this time.
2. Rotate the pump so the bleeder valve (125) is aligned
with the slot in the mounting bracket (233), and lift the
pump straight up through the bracket.
NOTE:
Perform step 3
only
if the air valve (165) or gas-
ket (166) need replacement. Otherwise, pro-
ceed to step 4.
3.
If it is necessary to replace the air valve (165) or
gasket (166),
unscrew the cylinder cap (101) from
the air motor cylinder (102). Unscrew the two socket
screws holding the air valve (165). Remove the air
valve and gasket.
DO NOT immerse the air valve (165) in solvent. To
clean the valve, use a brush and compressed air.
CAUTION
4. Remove the three screws (138) and washers (141)
holding the air motor coupling (105) to the cylinder
(102). Pull the cylinder straight up off the coupling un-
til the air valve housing assembly (103a) clears the
air motor piston (104).
5. Unscrew the air valve housing assembly (103a) from
the cylinder (102).
6. Unscrew the pilot setscrew (144) from the air motor
piston (104) and the fluid piston (106). Unscrew the
air motor piston from the fluid piston, and pull it
straight up out of the air motor coupling (105). Re-
move the large o–ring (103d) from the outer diameter
of the air motor piston, and the two small o–rings
(103b) from the inner diameter.
7. Unscrew the air motor coupling (105) from the fluid
housing (109). Pull the coupling straight up until it
clears the fluid piston (106). Remove the o–rings
(103c, 103e) from the coupling.
8. Hold the fluid piston (106) steady by inserting a small
screwdriver or punch into the 4 mm diameter hole
(A). Remove the screw (145) and lockwasher (135)
holding the priming piston (115) to the priming piston
rod (110).
9. Pull the priming piston rod (110) and fluid piston (106)
straight up out of the fluid housing (109). Remove the
pin (123), and unscrew the priming piston rod from
the fluid piston.
10. Unscrew the intake valve housing (111) from the fluid
housing (109). Remove the o–ring (161) from the in-
take valve housing.
11. Remove the intake valve (114) and valve stop (112)
from the intake valve housing (111).
12. Unscrew the wet–cup/packing nut (107). Remove
the u–cup packing (163) from the throat. Remove the
o–ring (162) from the wet–cup/packing nut.
13. Clean all parts with a solvent compatible with the fluid
you are pumping, and inspect for wear or damage.
REASSEMBLY
NOTE:
Lubricate all packings and o–rings with a com-
patible grease before reassembling.
1. Install the u–cup packing (163**) in the throat of the
fluid housing (109),
with the lips facing down. Install
the o–ring (162**) into the groove above the bearing
of the wet–cup/packing nut (107). Install the wet–
cup/packing nut in the fluid housing (109), and torque
to 35–37 N.m (298–314 in–lb).
2. Screw the priming piston rod (110) into the fluid pis-
ton (106) until the holes align. Install the pin (123) in
the holes. Carefully slide the assembled piston and
rod down through the wet–cup and fluid housing.
3. Place the intake valve (114**) onto the seat of the in-
take valve housing (111). Insert the valve stop (112)
into the intake valve housing, with the flat side facing
up. Be sure the valve stop (112) seats on the lip of the
intake housing. Lubricate the o–ring (161**). Bend it
into a kidney shape, then carefully push it into the in-
ner groove of the intake valve housing (111), to avoid
damaging it.
4. Apply thread lubricant to the lower threads of the fluid
housing (109). Bring the fluid housing and intake
valve housing (111) together, making sure the prim-
ing piston rod (110) passes straight through the valve
stop (1 12) and intake valve (1 14) installed in the
housing (111). Loosely screw the intake valve hous-
ing (111) onto the fluid housing (109), then torque to
35–37 N.m (298–314 in–lb).
5. Apply lubricant to the threads of the screw (145).
Hold the fluid piston (106) steady by inserting a small
screwdriver or punch into the 4 mm diameter hole
(A). Install the priming piston (1 15) onto the end of
the priming piston rod (1 10), using the screw (145)
and lockwasher (135). Torque to 1.7–2.3 N.m (14–20
in–lb).
6. Apply lubricant to the top threads of the fluid housing
(109). Screw the air motor coupling (105) onto the
fluid housing, and torque to 35–37 N.m (298–314 in–
lb).
7. Install the large o–ring (103e*) on the outer diameter
of the air motor coupling (105), and the small o–ring
(103c*) in the groove on the inner diameter of the
coupling.
