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7. Grasp the hex of the bevel pinion shaft in leather-covered
or copper-covered vise jaws and tap the rear face of the
Angle Housing with a soft hammer to pull the Bevel
Pinion Bearing (110). After the Angle Attachment is
disassembled, check all parts for damage or wear. If the
gear teeth on either piece of the Matched Bevel Gear Set
are worn or chipped, replace both parts. They are
furnished in a matched set and must be replaced with a
matched set.
8. Using a hooked tool, reach inside the Coupling Nut (108)
and pull the Coupling Nut Retainer (109) from the Nut.
Slide the Coupling Nut and Retainer off the motor end of
the Angle Attachment.
Disassembly of the Adjustable Cushion Clutch
and Adjustable Shutoff Clutch
1. Withdraw the Clutch Driver Assembly and the Bevel
Pinion Driver (77) from the Clutch Housing Assembly
(51).
2. Grasping the Clutch Return Spring (55) near the Spring
Seat Stop (66) to avoid elongating the Spring, pull the
Clutch Return Spring from the Clutch Driver (57).
3.
For Models ending in 1S5, 2S3 or 2S5,
remove the
Shutoff Plunger (72). Using a hooked tool to reach into
the end of the Clutch Driver, hook the Plunger Return
Spring (73) and pull it from the Driver.
4. Using a thin blade screwdriver, pry the Spring Seat Stop
off the Clutch Driver.
5. Clamping on the hex end of the Clutch Driver, place the
Clutch Driver vertically in leather-covered or copper-
covered vise jaws and unscrew the Adjusting Nut (68)
with an adjustable wrench. A bumping effect, caused by
the Adjusting Nut engaging and disengaging the
Adjusting Nut Lock (67), may be felt while loosening the
Nut.
6. Remove the Clutch Driver from the vise and remove the
Adjusting Nut, Adjusting Nut Lock, Thrust Bearing (64),
Clutch Spring Seat (65), and Clutch Spring (56) from the
Clutch Driver.
7.
For Models ending in 2C3 and 2C5,
using a thin blade
screwdriver, pry the remaining two Spring Seat Stops (66)
off the Clutch Driver.
NOTICE
Place a container under the assembly before removing
the retainer nearest the Clutch Ball Seat (63). Removal of
this retainer permits the Clutch Ball Seat, Clutch Ball
Spacer (61), and Clutch Jaw (58) to move rearward for
removal and allows the eleven Clutch Balls (59) and ten
Jaw Bearing Balls (60) to fall from the assembly.
For Models ending in 1S3, 2S3 and 2S5,
using a thin
blade screwdriver, pry the remaining Spring Seat Stop
(66) from the Clutch Driver.
NOTICE
Place a container under the assembly before removing
the Spring Seat Stop. Removal of this retainer allows the
three Clutch Cam Balls (74) to fall from the assembly.
Slide the Collar Return Spring (71), Shutoff Collar (70)
and Clutch Ball Seat (63) off the Clutch Driver. Using a
thin blade screwdriver, carefully pry off the Ball Retaining
Ring (69). Dump the ten Bevel Pinion Driver Bearing
Balls (75) in a container. Remove the Bevel Pinion Driver
(77) from the Clutch Driver. Remove the Clutch Driver
Seal (62) from the groove at the front end of the Clutch
Driver.
8. If the Clutch Housing Bushing (52) is worn, press it from
the Clutch Housing Assembly.
Disassembly of the Gearing
1. Using a thin blade screwdriver, work the Clamp Washer
Retaining Ring (50) from the groove in the Gear Case
Assembly (39) and withdraw the Motor Clamp Washer
(49).
2.
For M, N, O and Q ratios,
tap the motor end of the Gear
Case Assembly against the top of the workbench to
remove the Gear Head (47), Gear Head Planet Gears
(48), Pinion (45) (for M and N ratios) and Gear Head
Spacer (46).
3. Using a pair of snap ring pliers, remove the Spindle
Retaining Ring (44) from the groove in the front of the
Spindle (43).
4. Lightly tap or press the Spindle and Spindle Planet Gears
(42) from the Gear Case Assembly.
5. Using a pair of snap ring pliers, remove the Spindle
Bearing Retainer (41) from the groove in the front of the
Gear Case.
6. Using a sleeve that contacts the outer ring of the bearing,
press the Spindle Bearing (40) from the front of the Gear
Case.
Disassembly of the Motor
1. Grasp the splined end of the Rotor (29) and pull the
motor from the Motor Housing (1).
2. Withdraw the Rear End Plate Gasket (38) from the
bottom of the housing bore.
3. While grasping the Cylinder (36) in one hand, lightly tap
on the splined end of the Rotor to drive the Rotor from the
bore of the Front Rotor Bearing (32), thus freeing the
Front End Plate (30) and Bearing.
4. Using snap ring pliers, remove the Front Rotor Bearing
Retainer (34) and pull the Front Rotor Bearing from the
Front End Plate.
5. Slide the Cylinder off the Rotor, and withdraw the Vanes
(35) from the vane slots.
6. Remove the Rear Rotor Bearing Retainer (33) from the
groove in the hub of the Rotor.
7. Support the Rear End Plate (31) as close to the rotor
body as possible, and press the Rotor from the Rear
Rotor Bearing.
Disassembly of the Motor Housing
1. Using a 1/16” hex wrench, remove the Retainer Set
screw (7) from the Reverse Valve (3).
2. With the Reverse Valve facing downward, lightly tap the
Motor Housing (1) on the workbench until the Lock Pin
Retainer (8) falls out of the Reverse Valve.
3. While holding the Motor Housing horizontally with the
Throttle Lever (26) downward, press the Reverse Valve
slightly until the Valve Lock Pin (6) drops into the opening
vacated by the Lock Pin Retainer. You may have to tap
the Motor Housing lightly to jar the Lock Pin free.
4. Remove the Reverse Valve, Reverse Valve Seal (4),
Reverse Valve Spring (5) and Valve Lock Pin from the
Motor Housing.
WARNING
The Throttle Valve Cap (12) is under pressure from the
Throttle Valve Spring (10). Care must be exercised when
removing the Throttle Valve Cap.
5. Remove the Throttle Valve Cap, Throttle Valve Spring,
Throttle Valve Ball (13) and Throttle Valve Plunger (11)
from the Motor Housing and from the Throttle Valve
Housing (9) on 1RLS Models.
6. Remove the Inlet Bushing Assembly (27) and pull the
Exhaust Deflector (24) from the Motor Housing on Model
1RL and from the Throttle Valve Housing (9) on Model
1RLS.
