ARO PG087A-A5 User manual

ARO OPERATOR’SMANUAL SECTION
M35
89
INCLUDING: OPERATION,INSTALLATION& MAlNTENANCE Released: 8-1-97
Tool Products
IMPULSE WRENCH
MODEL: PG087A-A5
Model PG087A-A5 impulse Wrench is designed for assembly operations which require high speed
rundown of fasteners with consistent torque delivery and reduced torque reaction.
ARO is not responsible for customer modification of tools for applications on which ARO was not
consulted.
IMPORTANT SAFETY INFORMATION ENCLOSED,
READ THIS MANUAL BEFORE OPERATING TOOL.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION
IN THIS MANUAL INTO THE HANDS OF THE OPERATOR.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
PLACING TOOL IN SERVICE
l
Always operate, inspect and maintain this tool in
accordance with all regulations (local, state,
federal and country), that may apply to hand held/
hand operated pneumatic tools.
l
For safety, top performance, and maximum
durability of parts, operate this tool at 90 psig
(6.2 bar/620 kPa) maximum air pressure at the
inlet with 3/8” (10 mm) inside diameter air supply
hose.
l
Always turn off the air supply and disconnect the
air supply hose before installing, removing or
adjusting any accessory on this tool, or before
performing any maintenance on this tool.
. Do not use damaged, frayed or deteriorated air
hoses and fittings.
. Be sure all hoses and fittings are the correct size
and are tightly secured. See Dwg. TPD905-1 for a
typical piping arrangement.
l
Always use clean, dry air at 90 psig
(6.2 bar/620 kPa) maximum air pressure. Dust,
corrosive fumes and/or excessive moisture can ruin
the motor of an air tool.
l
Do not lubricate tools with flammable or volatile
liquids such as kerosene, diesel or jet fuel.
l
Do not remove any labels. Replace any damaged
label.
USING THE TOOL
l
Always wear eye protection when operating or
.
.
.
.
.
.
.
.
.
.
.
Always wear hearing protection when operating this-
tool.
Keep bands, loose clothing and long hair away from
rotating end of tool.
Note the position of the reversing lever before
operating the tool so as to be aware of the direction of
rotation when operating the throttle.
Anticipate and be alert for sudden changes in
motion during start up and operation of any power
tool.
Keep body stance balanced and firm. Do not over-
reach when operating this tool. High reaction
torques can occur at or below the recommended
air pressure.
Tool shaft may continue to rotate briefly after
throttle is released.
Air powered tools can vibrate in use. Vibration,
repetitive motions or uncomfortable positions may
be harmful to your hands and arms. Stop using any
tool if discomfort, tingling feeling or pain occurs.
Seek medical advice before resuming use.
Use accessories recommended by ARO.
Use only impact sockets and accessories. Do not use
hand (chrome) sockets or accessories.
Impact wrenches are not torque wrenches.
Connections requiring specific torque must be
checked with a torque meter after fitting with an
impact wrench.
This tool is not designed for working in explosive
atmospheres.
performing maintenance on this tool.
The use of other than genuine ARO replacement parts may result in safety hazards, decreased tool performance, and
increased maintenance, and may invalidate all warranties.
Repairs should be made only by authorized trained personnel. Consult your nearest ARO Tool Products Authorized
Servicenter.
For parts and service information, contact your local ARO distributor, or the Customer Service Dept. of the Ingersoll-Rand Distribution Center,
White House, TN at PH: [phone], FAX: [phone]
ARO Tool Products
Ingersoll-Rand Company
ARO
1725 U.S. No. 1 North, PO Box 8000, Southern Pines, NC 28388-8000
©1997 INGERSOLL-RAND COMPANY PRINTED IN U.S.A.
Part of worldwide Ingersoll-Rand

WARNING LABEL IDENTIFICATION
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
WARNING
Air pousnd toob 8m”vlbrata
In U... vlbmuon, np.tllhm
-wuncomlort9bbpo-
duon* my b hwdul to your
huukmdwmm. stopuhg
my tool If dbcomfut, tlngllng
fooling or ~WI occum. 8-k
medbal l dvlc* b&m “*urn
WARNING
KWD bodv atmnca bakmad
l d’flm -Do not overreach
when opmmtlng thh tool. I
ADJUSTMENTS
TORQUE ADJUSTMENT
Toadjustthetorqueon theseTwin BladeImpulse
Wrenches,proceedasfollows:
1. RemovetheAdjustment Hole Plug.
2. Rotatethe Drive Shaftuntil theTorqueAdjustment
Screwis visible in the opening.
3. Using a 1.5mm hex wrench, rotatetheAdjustment
Screwclockwise to increasethetorqueoutput and
counterclockwise to decreasethe torqueoutput.
Do not rotatethe Oil Plug.
Make all final adjustments at the job.
4. ReplacetheAdjustment Hole Plug.
CHANGING THE MECHANISM FLUID
Tochangethe MechanismFluid in theImpulse Mechanism,
proceedasfollows:
1. Useapointed probeto pushtheSpring Seat
againsttheRetaining SleeveSpring. While the
Spring is compressed,useanotherpointed probeor
thin bladescrewdriver to removethe Retaining
Ring. Lift theSpring Seat,Spring andBit
Retaining Sleeveoff theDrive Shaftand
removetheBit Retaining Ball.
2. Using snapring pliers, removethe Retaining Sleeve
Spring Stopfrom the Drive Shaft.
3. RemovetheRubberHousing Boot.
4. Using copper-coveredvisejaws, carefully graspthe
flats of theMechanism Coverwith theoutput end
of theDrive Shaftdownward.
5. Using anadjustablewrench, unscrewthe Motor
Housing Assemblyfrom theMechanism Cover.
This is a left-hand thread, rotatethe Motor Housing
clockwise to removeit. SeeDwg. TPD1264.
CLOCKWISE TO LOOSEN
(Dwg. TPD1264)
6. Lift theassembledmotor off the MechanismCover
andpull the mechanismassemblyout of the Cover.

ADJUSTMENTS
7.
8.
9.
10.
Using a 1.5mm hex wrench, rotatetheTorque
Adjustment Screwclockwise until the Screw
stops.RotatetheScrewcounterclockwise until it stops
or makessix completerevolutions.
Using thespecialTeeWrenchfurnished in theTool Kit
(PartNo. l00PQ-99), removethe Oil Plug and
Oil Plug Seal.
With theoil plug opening downward over acontainer,
rotatetheDrive Shaftto purgethefluid from the
mechanism.
Using thesyringe andfluid from the Fluid
ReplacementKit (PartNo. EQ106S-K400), fill the
mechanismwith thefluid furnished in the Kit.
SeeDwg. TPD1265.
DO NOT SUBSTITUTE- ANY OTHER FLUID.
Failure to use the fluid provided could damage the
tool, increase maintenance and decrease
performance. Use only clean fluid in these tools.
11.Submergethefill opening in the remainderof the
fluid, andusing awrench, rotatethe Drive Shaftto
purgeany remaining air from thesystem.
12.
13.
14.
15.
16.
17.
Threadthe Oil Plug with the Oil Plug Sealinto the
mechanismuntil it is snug.
Using a1.5 mm hex wrench, turn theTorque
Adjustment Screwclockwise until it stops.This is the
maximum torqueposition.
Wipe theoutsideof the mechanismdry andcleanand
removethe Oil ChamberPlug. Using thesyringe,
withdraw 0.25cc of fluid.
Install the Oil ChamberPlug andtighten it between20
and25in-lb (2.3and2.8 Nm) torque.
Insert themechanismassembly,output endleading,
into theMechanism Coverclampedin thevisejaws.
Insert the hex endof the rotor shaftinto the hex recess
at the rearof the Drive Shaftandthreadtheassembled
Motor Housing onto the Mechanism Cover.This is a
left-hand thread. RotatetheHousing
counterclockwise to tighten it. SeeDwg. TPD1266.
COUNTERCLOCKWISE TO TIGHTEN
(Dwg. TPD1265) (Dwg. TPD1266)

PLACING TOOL IN SERVICE
LUBRICATION
Ingersoll-Rand No. 50 Ingersoll-Rand No. 67
Ingersoll-Rand Fluid Part
No. EQ106S-400-l
Always useanair line lubricator with thesetools.
Werecommendthefollowing Filter-Lubricator-Regulator
Unit:
For USA - No. C22-04-G00
International - No. C16-C3-A29
After each 20 000 cycles, or asexperienceindicates, drain
andrefill the Impulse Unit Drive Assemblyasinstructed in
this manualusing the Fluid ReplacementKit
(PartNo. EQ106S-K400). Lubricate thehex drive andthe
output shaft beforeassembly.
MAIN LINES 3 TIMES
AIR TOOL INLET SIZE
BRANCH LINE 2 T
AIR TOOL INLET SIZE
DRAIN REGULARLY COMPRESSOR
(Dwg. TPD905-1)
HOW TO ORDER AN IMPULSE WRENCH
PISTOL GRIP with l/4” INSERT BIT CHUCK
Model Free Speed
PG087A-A5 9300
Recommended Torque Range
Soft Draw Hard Slam
ft-lb Nm ft-lb Nm
3-6 I 4-8 3-8 I 4-11

MAINTENANCE SECTION

5
6
7
8
9
10
11
12
13
14
15
16
+ 17
18
19
20
21
+ 22
23
24
25
+ 26
27
28
+ 29
30
PART NUMBER FOR ORDERING
Motor Housing Assembly ............
Motor Housing ..................
Throttle RodAssembly ............
Throttle RodSeal..............
Throttle ValveAssembly ...........
Throttle Valve Seal. ............
Throttle Valve Retainer ............
Throttle Bushing Assembly .........
Throttle Bushing Seal ..........
ReverseValve. ..................
ReverseValve Detent Ball. .........
ReverseValve DetentSpring. .......
ReverseLever ...................
ReverseLever Retaining Pin ........
Trigger ........................
Trigger Retaining Pin. .............
Throttle Retaining Pin .............
RearMotor Seal(2) ...............
ExhaustDeflector Assembly ..........
DeflectorRetaining Pin ..............
Hanger ...........................
RearEnd PlateAssembly. ............
RearRotor Bearing ..............
CylinderAssembly. .................
End PlateDowel (2). ..............
Rotor ............................
JanePacket(setof 7 Vanes) ..........
FrontEnd PlateAssembly ............
End PlateAlignment Pin ...........
Front Rotor Bearing. ..............
FrontEnd PlateSpacer ..............
l00PQ-A40
100PQ-40
EQ112P-A302
EQ106P-288
EQ106P-A304
100PQ-288
EQ106P-303
lOOPQ-A503
EQ106P-283
lOOPQ-329
EQ104S-929
100PQ-568
lOOPQ-328
180SQ-152
EQ106P-93
EQ106P-265
lOOPQ-297
380PQ-236
180PQ-A23
EQ106P-152
EQ106S-365
lOOPQ-A12
lOOPQ-22
lOOPQ-A3
lOOPQ-298
lOOPQ-53
IOOPQ-42-7
lOOPQ-All
lOOPQ-298
5OOA-22
lOOPQ-41
31
32
33
34
35
35A
36
36A
37
38
39
40
41
42
43
44
45
46
PART NUMBER FOR ORDERING
ImpulseUnit Drive Assembly
for old style units ................
for newstyle units ...............
Liner Housing
for old style units ................
for newstyle units ... ........
Oil Plug ............................
Oil Plug Seal ........................
TorqueAdjustment Bolt Assembly .......
Adjustment Bolt Seal...............
SealWasher ......................
Seal Back-up Ring.................
Adjustment Bolt StopRing (for new
style units only) ......................
Housing Cap. ........................
RearLiner CoverAssembly. ............
RearLiner Cover O-ring. ............
Liner Assembly ......................
Liner RearPin (2) .................
Liner Front Pin (2) .................
Relief Valve .........................
Drive Shaft ..........................
BladeAssembly ......................
Blade Spring Pin (2) ................
lOOPQ-A200
lOOPQ-A2OOA
lOOPQ-31
lOOPQ-31A
180PQ-277
EQllOP-288
lOOPQ-A230A
EQ106S-288
34351631
380SQ-272
34351623
lOOPQ-207
lOOPQ-A212
IOOPQ-236
lOOPQ-A203
180PQ-298
lOOSQ-298
100PQ-222
100PQ-626
100PQ-A627
100PQ-120
+ IndicatesMotor Tune-up Kit part.
t IndicatesMechanismTune-up Kit part.

t
47
48
t 49
t 50
51
52
53
54
55
56
57
58
59
60
61
62
63
PART NUMBER FOR ORDERING
BladeSpring (2). . . . . . . . . . . . . . . . . . .
Front Liner CoverAssembly .........
Drive ShaftSeal ...................
SealBack-up Ring. ................
Retaining SleeveSpring Stop ........
MechanismCoverSpacer
for old style units .............
for newstyle units ............
Mechanism CoverAssembly ............
Mechanism Cover .................
Adjustment Hole Plug ..............
Bit ChuckAssembly ..................
Bit Retaining Ball .................
Bit Retaining Sleeve ...............
Retaining SleeveSpring. ............
Spring Seat
.......................
Retaining Ring ....................
RubberHousing Boot .................
Nameplate .........................
NameplateScrew(2) ..................
WarningLabel .......................
t IndicatesMechanismTune-up Kit part.
* Not illustrated.
lOOPQ-569
lOOPQ-A211
lOOPQ-237
lOOPQ-272
lOOPQ-303
lOOPQ-274
04351656
lOOPQ-A727
lOOPQ-727
lOOPQ-95
180PQ-A667
EQ104S-929
EQ104S-930
EQ104S-931
EQ104S-932
EQ104S-933
lOOPQ-2
PGO87A-A5-301
1OOPQ-322
WARNING-2-99
64
65
*
PART NUMBER FOR ORDERING
Oil Daily Label . . . . . . . . . . . . . . . . . . . . . ,
TwoSpeedTrigger Label. . . . . . . . . . . . . . .
Fluid ReplacementKit (includes Fluid
Syringe, Fill Tubeand4 oz. [31 mL] of
ReplacementFluid) . . . . . . . . . . . . . . . . . . .
ReplacementFluid (4 oz.) . . . . . .. . . . .
ReplacementFluid (1 gal.)
Motor Tune-up kit (includes illustrated
items17 [2], 22,26 and29). . . . . . . . . . . . .
MechanismTune-up Kit (includes
illustrated items33,35,36,39,47 [2],
49and 50) . . . . . . . . . . . . . . . . . . . . . . . . . .
RepairTool Kit (includes all thespecialized
tooling required to repair thesetools
andconsistsof two SpannerPlugs,a Tee
Wrenchwith aspecialtip, an O-ring
Installer Fixture andapressingfixture
thathasaDisassemblyArbor and
PressingSleeve) . . . . . . . . . . . . . . . . . . . . . .
5OOP-69
180PQ-68
EQ106S-K400
EQ106S-400-l
EQ106S-BF400-1
lOOPQX500
lOOPQ-K600
lOOPQ-99

- CHANGING THE MECHANISM FLUID -
TochangetheMechanismFluid in theImpulse Mechanism,
proceedasfollows:
1.
2.
3.
4.
5.
Useapointed probeto pushthe Spring Seat(58)
againsttheRetaining SleeveSpring (57). While the
Spring is compressed,useanotherpointed probeor
thin bladescrewdriver to removethe Retaining Ring
(59). Lift the Spring Seat,Spring andBit Retaining
Sleeve(56) off the Drive Shaft(44) andremovethe Bit
Retaining Ball (55).
Using snapring pliers, removetheRetaining Sleeve
Spring Stop(51) from the Drive Shaft.
Removethe RubberHousing Boot (60).
Using copper-coveredvisejaws, carefully graspthe
flats of the MechanismCover (53) with the output end
of theDrive Shaftdownward.
Using anadjustablewrench, unscrewtheMotor
HousingAssembly (1) from theMechanismCover.
This is a left-hand thread, rotatetheMotor Housing
clockwise to removeit. Referto Dwg. TPD1264.
6.
7.
8.
9.
10.
CLOCKWISE TO LOOSEN
(Dwg. TPD1264)
Lift the assembledmotor off theMechanismCoverand
pull the mechanismassemblyout of the Cover.
Using a 1.5mm hex wrench, rotatetheTorque
AdjustmentScrew(34) clockwise until theScrew
stops.RotatetheScrewcounterclockwiseuntil it stops
in newstyle Liner Housings. Do not rotatetheScrew
morethan3-1/2 turns counterclockwise in old style
Liner Housingsor theScrewwill fall out of the
Housing.
Using thespecialTeeWrenchfurnished in theTool Kit
(PartNo. 100PQ-99), removethe Oil Plug (32) and
Oil Plug Seal(33).
With theoil plug openingdownward over acontainer,
rotatetheDrive Shaftto purgethefluid from the
mechanism.
Using the syringe andfluid from the Fluid
ReplacementKit (PartNo. EQ106S-K4OO),fill the
mechanismwith thefluid furnished in the Kit. Referto
Dwg. TPD1265.
11.
12.
13.
14.
15.
16.
17.
DO NOT SUBSTITUTE ANY OTHER FLUID.
Failure to use the fluid provided could damage the
tool, increase maintenance and decrease
performance. Use only clean fluid in these tools.
(Dwg. TPD1265)
Submergethefill opening in the remainderof the
fluid, andusing awrench, rotatetheDrive Shaftto
purgeany remaining air from thesystem.
Threadthe Oil Plug with the Oil Plug Sealinto the
mechanismuntil it is snug.
Using a 1.5mm hex wrench, turn the Torque
Adjustment Screwclockwise until it stops.This is the
maximum torqueposition.
Wipe theoutsideof the mechanismdry andcleanand
removetheOil ChamberPlug. Using thesyringe,
withdraw .25ccof fluid.
Install the Oil ChamberPlug andtighten it between20
and25in-lb (2.3and2.8 Nm) torque.
Insert the mechanismassembly,output endleading,
into the Mechanism Coverclampedin thevisejaws.
Insert the hex endof the rotor shaftinto the hex recess
at the rearof the Drive Shaftand threadtheassembled
Motor Housing onto theMechanism Cover.This is a
left-hand thread. Rotatethe Housing
counterclockwise to tighten it. Referto Dwg.
TPD1266.
COUNTERCLOCKWISE TO TIGHTEN
--
(Dwg. TPD1266)
8

MAINTENANCE SECTION
DISASSEMBLY
General Instructions
1. Do not disassemblethe tool anyfurther thannecessary
to replaceor repair damagedparts.
2. Whengraspinga tool or partin avise, alwaysuse
leather-covered or copper-coveredvisejaws to protect
thesurfaceof thepart and help preventdistortion. This
is particularly true of threadedmembersandhousings.
3. Do not removeany part which is apressfit in or on an
assemblyunlessthe removal of that partis necessary
for repairsor replacement.
4. Do not disassemblethetool unlessyou havea
completesetof newgasketsandO-rings for
replacement.
Disassembly of the Impulse Mechanism
1. Useapointed probeto pushthe Spring Seat(58)
againsttheRetaining SleeveSpring (57). While the
Springis compressed,useanotherpointed probeor
thin bladescrewdriver to removethe Retaining
Ring (59). Lift the Spring Seat,Spring andBit
Retaining Sleeve(56) off the Drive Shaft(44) and
removetheBit Retaining Ball (55).
2. Using snapring pliers, removetheRetaining Sleeve
Spring Stop(51)from the Drive Shaft.
3. Removethe RubberHousing Boot (60).
4. Using copper-coveredvisejaws, carefully graspthe
flats of the MechanismCover (53) with the output end
of theDrive Shaftdownward.
5. Using anadjustablewrench, unscrewthe Motor
HousingAssembly (1) from theMechanismCover.
This is a left-hand thread, rotatethe Motor Housing
clockwise to removeit. (Referto Dwg. TPD1264.)
6. Lift theassembledmotor off the MechanismCover
andpull the mechanismassemblyout of theCover.
Removethe Bushing Spacer(52).
7. Using a 1.5mm hex wrench, rotatetheTorque
Adjustment Screw(34) clockwise until theScrew
stops.RotatetheScrewcounterclockwiseuntil it stops
in newstyle Liner Housings. Do not rotatetheScrew
morethan3-l/2 turnscounterclockwise in old style
Liner Housingsor theScrewwill fall out of the
Housing.
8. Using the specialTeeWrenchfurnished in theTool Kit
(PartNo. lOOPQ-99),removethe Oil Plug (32) and
Oil Plug Seal(33).
9. With theoil plug opening downward over acontainer,
rotatetheDrive Shaftto purgethefluid from the
mechanism.
10. Grasptheflats of the Housing Assembly (31) in vise
jaws with the output endof theDrive Shaftdownward.
11. Insert thepins of thespannerplug from the No.
lOOPQ-99Tool Kit into the two holesin the Housing
Cap(37). Using awrench on theplug, unscrewand
removethe Housing Gapfrom the Housing Assembly.
Referto Dwg. TPD1267.
- SPANNER PLUG COUNTERCLOCKWISE
TO LOOSEN
(Dwg. TPD1267)
12. Standthedisassemblyarborfrom theTool Kit, large
enddownward, on aworkbench or the tableof an
arbor press.Insert the output endof theDrive Shaft
into thecentral opening andeither taptheHousing
downward off the componentsor usethepressing
sleevein the Kit to presstheHousing downwardoff
the components.Referto Dwg. TPD1268.
TAP EDGE LIGHTLY
WITH BRASS HAMMER
OR USE PRESSING
SLEEVE FROM TOOL
HOUSING KIT
DISASSEMBLY ARBOR
FROM TOOL KIT
(Dwg. TPD1268)
13. Disassemblethe componentsof the mechanismin the
sequenceshownin Drawing TPA1609on Page5.
Disassembly of the Motor
1. GrasptheMotor Housing (1) in visejaws with the
shaftof theRotor (25) upward.
2. Insert thepins of theendplatespacerspannerinto the
holesin theFront End PlateSpacer(30). Using a
wrench, unscrewandremovethe Spacer.This is a
left-hand thread; rotatethewrench clockwise to
removetheSpacer.Referto Dwg. TPD1269.
9

MAINTENANCE SECTION
END PLATE
SPACER SPANNER
3.
4.
5.
6.
7.
CLOCKWISE
TO LOOSEN
(Dwg. TPD1269)
Reposition the Motor Housing in thevisejaws sothat
thevisejaws grip the endof the rotor shaftandthe
handlegrip of theHousing is downward. Tapthe edges
of theHousing surrounding themotor borewith a
plastic hammerto separatetheHousing from the
motor.Referto Dwg. TPD1270.
(Dwg. TPD1270)
Removethe motor from the visejaws andremovethe
Front End Plate(27), Front End PlateBearing (29),
Cylinder Assembly (25) andVanes(26) from the
Rotor.
Removethe two RearMotor Seals(17)from theMotor
Housing.
Onthe tableof anarbor press,supporttheRearEnd
Plate(21) with blocksascloseto the Rotor aspossible
andpressthe Rotor out of the RearEnd PlateandRear
Rotor Bearing (22).
In the following step, do not enlarge or damage the
shaft hole in the End Plate when removing the
Bearing.
To removetheRearRotor Bearing from the RearEnd
Plate,useasmall drift or pin punch through the central
opening of theRearEnd Plateto tap theBearing out of
theEnd Plate.Referto Dwg. TPD1271.
(Dwg. TPD1271)
8. Using apin punch, tapthe Throttle Retaining Pin (16)
andthe Deflector Retaining Pin (19) out of theHandle.
The Throttle Retaining Pin is protectedby an
embossedcircular padof metal. Insert the pin punch
into themiddle of the padto locate the Pin. Referto
Dwg. TPD1272.
9.
10.
11,
12.
13.
14.
TPD1272)
GrasptheTrigger (14) andpull theassembledthrottle
out of theMotor Housing.
Using apin punchandwithout damagingthe Trigger,
removetheTrigger Pin (15).
Being careful not to losethe ReverseValve Detent
Ball (10) or ReverseValve DetentSpring (ll), slide
the Throttle Bushing Assembly (7), Throttle Valve
Assembly (4) andThrottle RodAssembly (2) off the
ReverseValve (9).
Using apin punch andwithout damagingthe Reverse
Lever (12), removetheReverseLever Retaining
Pin (13) andseparatethe Lever from theValve.
Using athin bladescrewdriver, removetheThrottle
Valve Retainer(6) andslide the Throttle Valve
Assembly off the shaftof theThrottle Valve Rod.
GrasptheExhaustDeflector Assembly (18) andpull it
out of the Housing.
ASSEMBLY
General Instructions
1. Always presson the inner ring of aball-type bearing
when installing the bearingon ashaft.
10

MAINTENANCE SECTION
2. Always presson the outer ring of aball-type bearing
when pressingthebearinginto abearing recess.
3. Whengraspinga tool or partin avise, always use
leather-covered or copper-coveredvisejaws to protect
thesurfaceof thepartand help preventdistortion. This
is particularly true of threadedmembersandhousings.
4. Exceptfor bearingsandmechanismparts,always
cleanevery partandwipe every part with athin film of
oil beforeinstallation.
5. Wipe a thin film of mechanismfluid on all internal
mechanismcomponentsbeforeinstalling themin the
mechanism.
6. Apply afilm of o-ring lubricant to every o-ring before
installation.
Assembly of the Motor
1. Position the ExhaustDeflector Assembly (18) in the
bottomof themotor housing handleandinstall the
Deflector Retaining Pin (19) to secureit in position.
2.
3.
4.
It may be necessary to slide the Assembly in or out
in order to align the groove in the Assembly with
the pin hole.
Install theThrottle RodSeal(3) in the grooveon the
large hub of theThrottle Rod(2).
Install theThrottle Valve Seal(5) in the grooveon the
largehub of theThrottle Valve (4).
Slide theThrottle Valve,Valve Sealendfirst, onto the
Throttle Rod.
5. SecuretheThrottle Valve Assembly by installing the
Throttle Valve Retainer(6) in thesmall grooveon the
Throttle Rod.
6. Install theThrottle Bushing Seal(8) on the hubendof
theThrottle Bushing (7).
7
,. Position the Throttle Lever (12) on theReverse
Valve (9) andsecureit by installing theReverseLever
Retaining Pin (13).
8. Slide theThrottle Bushing Assembly,sealendleading,
onto theshaftof theThrottle Rod.
9. Slide theReverseValve,lever endtrailing, onto the
shaftof the Throttle Rodandinto theThrottle Bushing
until the detenthole in theValve reachestheendof the
Bushing.
10. Install the ReverseValve DetentSpring (11)followed
by the ReverseValve Detent Ball (10) in the hole in
the ReverseValve. While compressingtheSpring with
theBall, continue sliding theValve into the Bushing
until the DetentBall entersoneof the detentpockets
inside the Bushing.
11. Position theTrigger (14) on the shaftof the Throttle
Rodandsecureit by inserting the Trigger Retaining
Pin (15) through theTrigger andshaft.
12. Insert theassembledTrigger into the Motor Housing.
Make certain thewidest endof the Trigger is nearest
the motor boreandthenotch acrosstheoutsideof the
Throttle Bushing aligns with hole in the Motor
Housing for the Throttle Retaining Pin (16). Install the
Pin making certain it capturesandsecuresthe
assembledTrigger.
13. Using anarborpressandapieceof tubing that
contactstheouter ring of the bearings,pressthe Front
End PlateBearing (29) into the Front EndPlate(27)
andtheRearEnd PlateBearing (22) into theRearEnd
Plate(21). Referto Dwg. TPD1274.
TUBING
BEARING
END
PLATE
14.
15.
16.
17.
18.
19.
20.
StandtheRotor (25) on the tableof an arborpress.It
should beupright on aflat metal plate having a
clearanceholefor theshaft.The shaftwith the hex
mustbedownward.
Placea0.001” (0.025 mm)shim on the upwardsurface
of thelarge portion of the rotor body.Using apieceof
tubing that contactstheinner ring of thebearing, press
the RearRotor Bearing andRearEnd Plate,End Plate
leading, onto theshaftof the Rotor until the End Plate
contactstheshim. Removetheshim.
CoateachVane(26) with a thin film of oil and insert a
Vaneinto eachof the rotor vaneslotswith thestraight
edgeof theVaneoutward.
Install the Cylinder (23) over the VanesandRotor with
the endof the Cylinder having the two holesin straight
alignment nearesttheendfacepositioned awayfrom
the RearEndPlate.Make certain theEnd Plate
Dowel (24) entersthe hole in the faceof the RearEnd
Plateandnot the porting slot.
Placethe Front EndPlateandBearing againsttheface
of the Cylinder, Bearing endtrailing. Make certain the
End PlateDowel in that endof thecylinder entersthe
hole in the EndPlateandnot theporting slot.
Insert the two RearMotor Seals(17) in the bottomof
the Housing motor bore.
Insert theassembledmotor, RearEnd Plateleading,
into theMotor Housing making suretheEnd Plate
Alignment Pin (28) entersthepropernotch in the
Housing. It may benecessaryto taptheassemblyinto
position with a brassor plastic hammer.Referto
Dwg. TPD1279.
11

MAINTENANCE SECTION
21.
22.
(Dwg. TPD1279)
Graspthe handleof theMotor Housing in visejaws
with the rotor shaftupward. ThreadtheFront End
PlateSpacer(30) into theHousing andusing theend
platespacerspanner,tighten the Spacerto 33 ft-lb
(45Nm) torque.This is a left-hand thread; rotatethe
wrench counterclockwibe to tighten. Referto
Dwg. TPD1280.
COUNTERCLOCKWISE TO TIGHTEN
SPANNER
(Dwg. TPD1280)
After installing theFront End PlateSpacer,graspthe
shaftof the Rotor and rotateit by hand.If theRotor
doesnot turn easily,disassemblethe motor unit and
determinewheretheassemblyis binding. The motor
mustrotatefreely beforeproceedingfurther with the
assembly.
Assembly of the Impulse Mechanism
1. Install the RearLiner Cover O-ring (39) in theannular
groovearoundthe RearLiner Cover (38).
2. Insert theRelief Valve (43) into theLiner (40).
3. PlaceaBladeSpring (47) into eachhole in oneof the
slotsof theDrive Shaft(44).
4. PlacetheBlade (45) againstthe Springssothat each
Spring encirclesaBlade Spring Pin (46).
5. Compressthe Springswith the Bladeuntil theBlade is
flush with theDrive Shaftandinstall theassemblyin
theLiner with theoutput endof theDrive Shaft
protruding out theendof the Liner containing the
Relief Valve. (Referto Dwg. TPD1284.)Make certain
theendsof theBlade areflush with the endsof the
Liner.
6.
7.
8.
9.
10.
11.
12.
(Dwg. TPD1284)
Placethe RearLiner CoverAssemblyagainstthe
motor endof the Liner making surethat the two Liner
RearPins(41) enterthe holesin the Cover andthe rear
hub of theDrive Shaftentersthe central opening of the
Cover.
Install theFront Liner CoverAssembly (48) over the
Drive Shaftagainstthe spindle endof the Liner
making surethat the two Liner Front Pins(42) enter
the holesin the Coverand theRelief Valve aligns with
the opening in the Cover.
Install the Drive ShaftSeal(49) followed by theSeal
Back-up Ring (50) on theDrive Shaftagainstthe hub.
Referto Dwg. TPD1285.
SEAL BACK-UP RING
DRIVE SHAFT SEAL
(Dwg. TPD1285)
Install theassembledLiner andCoversin theLiner
Housing (31) making certain that the Relief Valve is in
alignment with the openingfor theTorqueAdjustment
Bolt (34).
Install theAdjustment Bolt Seal(35) followed by the
SealWasher(35A) andSealBack-up Ring (36) on the
TorqueAdjustment Bolt andthreadtheassembledBolt
into theLiner Housing.
Install theAdjustment Bolt StopRing (36A) in the
groove of theLiner Housing to keeptheBolt Assembly
from backing out.
Install the Oil Plug (32) and Oil Plug Seal(33) in the
liner housing hole 180degreesfrom theTorque
Adjustment Bolt.
12

14

PN49999-531