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Disassembly of Extension Assembly on G2E and G2L
Models
Grasp the tool mounted in the Clamp Tool (96), in softsided vise
jaws with the Spindle (64 or 45) upward. Using the Clamp nut
Wrench (95) on the flats of the Extension Housing (43 or 61),
unscrew and remove the assembled Housing. This is a
left-hand
thread
. Rotate the Housing
clockwise
to remove it. Remove the
Arbor Coupling (39 or 57) and Clamp Sleeve (40 or 58).
For G2E models
, using snap ring pliers, remove the Coupling
Retaining Ring (42) from the Spindle Bearing Nut (41) in the large
end of the Extension Housing.
After removing the Retaining Ring, push on the Nut end of the
Spindle until the assembled Spindle exits the angle head end of
the Extension Housing. The Rear Spindle Bearing (44) will remain
in the Housing and the Nut will pass through the Bearing.
If the Front Spindle Bearing (46) must be replaced, use a 1/2”
wrench on the flats of the Bevel Pinion (47) and the Spindle
Bearing Nut to unscrew and remove either the Pinion or Nut.
Using an adjustable wrench on the flats of the Spindle, remove
whichever component remained threaded onto the Spindle. Press
the Bearing from the Spindle.
If the Rear Spindle Bearing must be replaced, press the Bearing
out of the large end of the Extension Housing.
For G2L models
, grasp the Bevel Pinion (66) and pull the
assembled Spindle from the Extension Housing. Remove the two
Rear Spindle Bearing Washers (63) from the Housing.
Using snap ring pliers, remove the Coupling Retaining Ring (60)
from the Spindle Bearing Nut (59) on the assembled Spindle.
Grasp a 5/32” diameter steel pin vertically in a set of vise jaws and
slide the crosshole of the assembled Spindle down onto the pin.
Using a 1/2” wrench, unscrew and remove the Spindle Bearing
Nut.
Using a 9/16” wrench, unscrew and remove the Bevel Pinion.
Using a bearing puller, pull the Rear Spindle Bearing (62) off the
Spindle.
Using a bearing puller or arbor press, pull or press the Front
Spindle Bearing (65) off the Spindle.
Disassembly of the Motor
Remove the Flange clamp (35) and front Housing Cap (34) from
the front of the Motor Housing Assembly (12). Remove the Front
Muffler (33) if it remains in the Housing.
Grasp the Bevel Pinion (66) or Spindle Bearing Nut (41 or 59) and
pull the assembled motor out of the Motor Housing. Remove
the two Rear Rotor Bearing Spacers (26) from the bottom of the
Cylinder (17).
Remove the Vanes (28) from the Rotor (27).
Grasp the Rotor in smooth sided vise jaws with the Bevel Pinion
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or Spindle Bearing Nut upward. Using a 1/2” wrench for the Nut
or a 9/16” wrench for the Pinion, unscrew and remove the Pinion
or Nut.
If the Front Rotor Bearing (32) must be replaced, support the
Front End Plate (29) between two blocks on the table of an
arbor press. Place the blocks as close to the body of the Rotor
as possible and press the Rotor from the Bearing and End Plate.
Remove the Front End Plate Spacer (30) and Seal Assembly (31)
from the hub of the Rotor.
If the Rear Rotor Bearing (25) must be replaced, use snap ring
pliers to remove the Rear Rotor Bearing Retainer (24).
Using a bearing puller, pull the Rear Rotor Bearing off the hub of
the Rotor.
Disassembly of the Inlet and Throttle
Using a 15/16” wrench or six point socket, unscrew and remove
the Inlet Assembly (1).
Remove the Inlet Seal (2), Inlet Screen and Ball Valve Spring Seat
from the Inlet.
Remove the Ball (4) and Ball Valve Spring (3) from the Cylinder
Assembly (17).
Press the Throttle Lever Pin (7) from the Rear Exhaust Diffuser (5)
and remove the Lever Assembly (9).
Remove the Rear Exhaust Diffuser from the Housing. Remove Rear
Exhaust Diffuser Gasket (8), Rear Exhaust Diffuser Muffler (10) and
Lever Support (6) from the Diffuser.
If the Ball Valve Seat (16) must be replaced, insert a hooked
tool through the central opening of the Seat and, catching the
underside of the Seat, pull it from the Housing.
Remove Rear Housing Muffler (11) from the Housing.
Push throttle Pin Assembly (18) out of Housing and remove from
opening in Cylinder.
Remove Throttle Pin O-Ring (19) from throttle Pin.
Disassembly of Motor Housing and Cylinder
Place Cylinder, Inlet end down, on flat hard surface. Grasp
Housing and pull down to separate it from the Cylinder. Pull
Cylinder out of Housing.
Remove Flow Guide Assembly (20) and Intake Cover Assembly
(22) from Exhaust Seal (14).
Remove Flow Guide O-Rings (21) from Flow Guide.
Remove Intake Cover O-Ring (23) from Intake Cover.
Remove Rear Cylinder O-Ring (13) and then the Exhaust Seal from
the Cylinder.
Remove Front Cylinder O-Ring (15) from the Cylinder.
If the Throttle Bushing needs to be replaced, insert a small hooked
tool into the hole in the bushing and catch the underside. Pull
Bushing from Cylinder.
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Assembly
General Instructions
Always press on the inner ring of a ball-type bearing when
installing the bearing on a shaft.
Always press on the outer ring of a ball-type bearing when
pressing the bearing into a bearing recess.
Whenever grasping a tool or part in a vise, always use soft-sided
vise jaws. Take extra care not to damage threads or distort
housings.
When grasping a tool in a vise, first place the tool housing in the
provided Clamp Tool (38), then grasp outer surface of Clamp Tool
in the vise to protect the housing from damage.
Except for bearings, always clean every part and wipe every part
with a thin film of oil before installation.
Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in clean solvent and dry with a clean
cloth. Sealed or shielded bearings should not be cleaned. Work
grease into every open bearing before installation.
Apply a film of O-Ring lubricant to every O-Ring before
installation.
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Unless otherwise noted, always press on the stamped end of a
needle bearing when installing a needle bearing into a recess.
Assembly of Motor Housing and Cylinder
If the Throttle Bushing was removed, Properly secure the Cylinder
(17) and press the Throttle Bushing into the hole on the side of
the Cylinder closest to threaded opening.
Apply O-Ring lubricant to the Front Cylinder O-Ring (15) and
install onto the small end of Cylinder. Slide O-Ring past all inlet
and exhaust slots, into Front O-Ring groove.
Install Exhaust Seal (14) onto small end of Cylinder and move it
all the way down over O-Ring. Line up and seat protrusion on
Exhaust Seal with slot in Cylinder for proper orientation.
Install the Rear Cylinder O-Ring (13) onto small end of Cylinder.
Slide O-Ring into rear O-Ring groove in Cylinder.
Install two Flow Guide O-Rings (21) in grooves on Flow Guide (20).
Install Intake Cover O-Ring (23) in groove on Intake Cover (22).
Assemble Flow Guide onto Cylinder. Be sure O-Rings are installed
on the Flow Guide before assembly. For rear exhaust insert the
rubber plugs on the Flow Guide into the holes in the Exhaust Seal.
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