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7. If the Clutch Housing Bearing (76) is worn and must be replaced,
press it from the Clutch Housing.
8. Carefully remove the Clutch Assembly, the
Clutch Input Driver (41 or 60), the Clutch Return Spring (40 or 59),
and the Push Rod (61).
9. Lightly grasp the flats of the Gear Case in leather covered or
copper-covered vise jaws with the Inlet Bushing (10) upward.
10. Place a 1-3/16” open end wrench on the flats of the Back Cap (5)
to prevent it from rotating, and use a 3/4” wrench to unscrew and
remove the Inlet Bushing.
11. Lift the Exhaust Diffuser (9) off the Back Cap and remove the
assembly from the vise.
12. Holding the assembly horizontally, remove the Back Cap, the
Memory Chip (8) (if included with the tool), the
Back Cap Gasket (6) and the Shutoff Valve (14).
13. If the Muffler Elements (7) need to be cleaned or replaced, pull
them out of the Back Cap.
14. Using one 1-1/16” wrench on the flats of the Motor Housing (1),
unscrew and separate the Gear Case from the Motor Housing.
15. Set the assembled Gear Case on the workbench.
16. Remove the Motor Clamp Washer (27) and the Motor Seal (26)
from the assembled motor in the Housing.
17. Tap the Motor Housing on a wood block to remove the Motor
Assembly from the Housing.
Disassembly of the Adjustable Shutoff Clutch
1. Using a thin blade screwdriver, pry the Clutch Adjusting Nut Stop
(58) off the end of the Clutch Shaft (46).
2. Insert the tip of a #1 Phillips Head Screwdriver into the
adjustment opening between the Clutch Adjusting Nut (57) and
the Clutch Adjusting Nut Washer (56). Rotate the screwdriver
clockwise to thread the Adjustment Nut off the Clutch Shaft.
NOTICE
In the following step, the Clutch Cam Balls will be free to fall from
the assembly when the Cam Ball Seat is moved. Make certain the
Balls fall into a non-damaging container.
3. Holding the assembly over a small pasteboard box, slide the
Adjusting Nut Washer, the Thrust Bearing (55), the Spring Seat
(54), the Clutch Spring (53) and the Cam Ball Seat (52) off the
Clutch Shaft. Allow the three Clutch Cam Balls (50) to fall into the
pasteboard box.
4. The Clutch Cam Ball Driver (49) has a cross hole that is larger on
one side than the other. Insert a 1/16” drill shank or piece of wire
into the smaller hole and gently push the Clutch Driver Retaining
Pin (51) out of the larger hole and out of the Driver and the Clutch
Shaft.
NOTICE
In the following step, the Clutch Balls will be free to fall from the
assembly when the Cam Jaw is moved along the Clutch Shaft.
Make certain the Balls fall into a non damaging container.
5. Holding the assembly over a small pasteboard box, and using
care to drop the twelve Clutch Balls (47) into the box, slide the
Clutch Cam Ball Driver and Cam Jaw (48) off the Clutch Shaft. If
grease held some of the Balls inside the jaw cavity, remove them.
6. With the large end of the Clutch Shaft downward, depress the
Automatic Shutoff Pin (44) with varying amounts of finger
pressure while tapping the large end edge of the Clutch Shaft
on a piece of wood until the Automatic Shutoff Plunger (42)
protrudes slightly from the end of the Shaft. Grasp the Plunger
and carefully pull it out of the Clutch Shaft.
7. Remove the Automatic Shutoff Pin and Automatic Shutoff Pin
Spring (45) from the Clutch Shaft. The Pin Spring should remain
in the pin recess when the Pin is removed. To separate the Spring
from the Pin, gently rotate the Spring while pulling it from the
recess to avoid elongating the Spring.
8. Using a hooked tool, reach into the opening in the end of the
Clutch Shaft and carefully pull the Automatic Shutoff Plunger
Return Spring (43) out of the Shaft without elongating the Spring.
Disassembly of the Gearing
1. Using snap ring pliers, remove the Gear Retainer (29) from the
motor end of the Gear Case (37) and remove the Gear Head
Spacer (30) as well.
2.
For Series QS1P02, QS1P05 and QS1P10
, lightly rap the motor
end of the Gear Case on a wooden work bench top to remove the
three Planet Gears (33), the Planet Gear Head Assembly (32) and
the Planet Gear Head Spacer (35).
3.
For Series QS1P15 and QS1P20
, lightly rap the motor end of
the Gear Case on a wooden work bench top to remove the three
Planet Gears (33), the Gear Head Pinion (34), the Planet Gear
Head Assembly (32) and the Planet Gear Head Spacer (35).
4.
For Series QS1P28
, lightly rap the motor end of the Gear Case on
a wooden work bench top to remove the Planet Gear Head Drive
Plate (31), the Planet Gear Head Assembly (32) and the
Planet Gear Head Spacer (35).
5. Using snap ring pliers, remove the Spindle Bearing
Retaining Ring (39).
6. Stand the Gear Case on the table of an arbor press with the
output spindle upward. Using a rod that neatly fits inside the
internal hex. of the Spindle (36), press the Spindle Assembly out
of the Spindle Bearing (38).
CAUTION
Do not remove the Bearing in the following step unless you have
a new replacement available for installation. The Bearing will be
damaged by the removal process.
7. Invert the Gear Case on the table of an arbor press so that the
end face having four notches makes contact with the table. Using
a rod against the inner race of the Spindle Bearing, press the
Bearing from the Gear Case.
8. If the Spindle Bearing Seat (39A) must be replaced, use a small,
thin blade screwdriver to spiral it out of the groove in the
Gear Case.
Disassembly of the Motor
1. Using snap ring pliers, remove the Rear End Plate Assembly
Retainer (17) from the shaft of the Rotor (21).
2. Pull the Rear End Plate Face Plate (16) and Rear End Plate
Assembly (15) off the hub of the Rotor.
3. Lift the Cylinder (18) from the Rotor.
4. Remove the Vanes (22) from the Rotor.
5. Support the Front End Plate Assembly (23), as near the rotor body
as possible, on the table of an arbor press and press the Rotor
from the Front Rotor Bearing (25). Remove the Bearing from the
Front End Plate
Disassembly of the Housing
1. Pull the Reverse Lever (13) off the inlet end of the
Motor Housing (1).
2. Using a #2 Phillips Head Screwdriver, unscrew and remove the
Housing Screw (3).
3. Insert a 5/16” wooden dowel between 6 and 8 inches long, into
the inlet end of the Motor Housing and push the Reverse Valve
Assembly (4) out the motor end of the Housing.
4. Use a hooked tool to pull the Housing O-Ring (2) out of the
Motor Housing.
