4
47143300_ed1
General Instructions
1. When grasping a tool or part in a vise, always use leather–covered
or copper–covered vise jaws to protect the surface of the part
and help prevent distortion. This is particularly true of threaded
members and housings.
2. Always press on the inner ring of a ball–type bearing when
installing the bearing on a shaft.
3. Always press on the outer ring of a ball–type bearing when
pressing the bearing into a bearing recess.
4. Except for bearings and mechanism parts, always clean every part
and wipe every part with a thin fi lm of oil before installation.
5. Wipe a thin fi lm of mechanism fl uid on all internal mechanism
components before installing them in the mechanism.
6. Apply a fi lm of O–ring lubricant to every O–ring before
installation.
Assembly of the Motor
1. If the Reverse Valve Bushing (7) was removed from the Motor
Housing (1), press it into the Housing, lug end trailing, from the
side of the Housing opposite the lever position. Make certain the
ports align with the bushing holes.
2. Thread the Inlet Bushing (14) into the threaded hole at the rear of
the handle of the Motor Housing and tighten it between 30 and
35 ft-lb (40 and 47 Nm) torque.
3. Position the Exhaust Defl ector Assembly (15) in the hole at
the rear of the motor housing handle and install the Defl ector
Retaining Pin (16) to secure it in position.
NOTICE
It may be necessary to slide the Assembly in or out in order to
align the groove in the Assembly with the pin hole.
4. Install two new Reverse Valve Bushing Seals (8) in the grooves
inside the Reverse Valve Bushing, if they were removed.
5. Install the Reverse Valve Seal (6) in the groove next to the large
hub of the Reverse Valve (5).
6. Install the Reverse Valve Assembly, seal and trailing, into the lever
side of the Motor Housing. Make certain the square depression
on the shaft of the Valve faces forward toward the output end of
the tool.
7. Install the Reverse Lever Seal (3) in the groove on the small hub of
the Reverse Lever (2).
8. Insert the Throttle Ball (12) followed by the Throttle Valve Spring
(11) into the Reverse Valve Assembly.
9. Position the Reverse Lever Assembly on the Reverse Valve
Assembly with the indicator lever rearward. Make certain the
crossholes in the Lever align with the pin holes in the Valve. Press
the Knob Retaining pin (4) into the Lever and Valve.
10. Insert the Throttle Plunger (13) into the Reverse Valve Assembly.
11. Position the Throttle Lever (9) on the Motor Housing and secure it
by pressing the Throttle Lever Pin (10) into the Housing and Lever.
12. Using an arbor pres and a piece of tubing that contacts the outer
ring of the bearings, press the Front Rotor Bearing (26) into the
Front End Plate (24) and the Rear Rotor Bearing (19) into the Rear
End Plate (18). (Refer to Dwg. TPD1300).
Bearing
Tubing
End Plate
(Dwg. TPD1300)
13. Stand the Rotor (22) on the table of an arbor press. It should be
upright on a fl at metal plate having a clearance hole for the shaft.
The shaft with the hex must be upward.
14. Place a 0.001” (0.025mm) shim on the upward surface of the large
portion of the rotor body. Using a piece of tubing that contacts
the inner ring of the bearing, press the Front Rotor Bearing and
Front End Plate, End Plate leading, onto the shaft of the Rotor
until the End Plate contacts the shim. Remove the shim. (Refer to
Dwg. TPD1301).
Pressign Plug
Front Rotor
Bearing
Rotor
Plate with Rotor
Shaft clearance
Front End Plate
0.001” (0.025 mml
Shim space
(Dwg. TPD1301)
(Dwg. TPD1299)
7. Press the Reverse Lever Pin (4) out of the Reverse Lever (2) and
remove the Reverse Lever, Reverse Lever Seal (3), Throttle Valve
Spring (11) and the Throttle Ball (12).
8. Spread the end of the Suspension Bail (17), where the ends enter
the Motor Housing, and remove the Bail.
9. Using a pin punch, tap the Throttle Lever Pin (10) and the
Defl ector Retaining Pin (16) out of the Handle. Remove the
Throttle Lever (9), Throttle Plunger (13) and the Exhaust Defl ector
Assembly (15).
10. Push the Reverse Valve Assembly (5) out the throttle lever end of
the Housing and Remove the two Reverse Valve Bushing Seals (8)
if they need to be replaced.
11. Unscrew and remove the Inlet Bushing (14).
12. If the Reverse Valve bushing (7) must be replaced, press it from
the Motor Housing.
Assembly