18
308302
Service
Reassembly (See Fig. 5)
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). Apply
thread lubricant and install the wet-cup/packing nut
in the fluid housing (109). Torque to 35–37 N
S
m
(298–314 in-lb).
2.
Screw the priming piston rod (110) into the fluid
piston (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
intake 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 pish it into the inner 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 priming piston rod (110) passes straight
through the valve stop (112) and intake valve (114)
installed in the housing (111) onto the fluid housing
(109), then torque to 35–37 N
S
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 4mm diameter
hole (A). Install the priming piston (115) onto the
end of the priming piston rod (110), using the
screw (145) and lockwasher (135). Torque to
1.7–2.3 N
S
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
S
m
(298–314 in-lb).
7.
Install the large o-ring (103e*) on the outer diame-
ter of the air motor coupling (105), and the small
o-ring (103c*) in the groove on the inner diameter
of the coupling.
8.
Install the two small o-rings (103b*) in the grooves
of the inner diameter of the air motor piston (104).
lower the piston through the air motor coupling
(105) so it engages the threads of the fluid piston
(106). Screw the air motor piston onto the fluid
piston, aligning the holes to obtain maximum
threads engagement. Insert the pin (144) in the
holes.
9.
Install the large o-ring (103d*) on the outer diame-
ter of the air motor piston (104).
10. Apply adhesive to the threads of the housing
assembly (103a*) and screw the assembly into the
air motor cylinder (102). Torque to 8–10 N
S
m
(72–88 in-lb). Apply lubricant to the outer diameter
of the air valve housing assembly (103a) and the
inner diameter of the air motor cylinder (102).
11. Lower the air motor cylinder (102) onto the air
motor coupling (105). Align the air inlet with the
fluid outlet, as was noted in step 1 under Disas-
sembly. The air valve housing assembly (103a)
will slide down into the air motor piston (104).
Secure the cylinder to the coupling with three
screws (138) and washers (141). Torque the
screws to 2–4 N
S
m (17–33 in-lb).
12. If it was necessary to replace the air valve (165)
align and install the new air valve on the top of the
air motor cylinder (102), as shown in Fig. 4. Install
the two mounting screws and washers and torque
to 2–4 N
S
m (17–33 in-lb). Lubricate the upper
threads of the air motor cylinder (102). Screw the
cylinder cap (101) onto the cylinder.
13. Lower the pump through the mounting bracket
(33). Orient it in the correct direction and secure to
the bracket using the three screws (138) and
washers (141). Torque the screws to 2–4 N
S
m
(17–33 in-lb). Reinstall the fluid outlet fitting (28).
14. Reinstall the wiper plate assembly on the fluid
intake housing (111). Secure with the two cap-
screws (302). Reconnect all hoses and return the
pump to service.
