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Disassembly of the Motor
Using snap ring pliers, remove the Rear End Plate Assembly
Retainer (32) from the shaft of the Rotor (36).
Pull the Rear End Plate Face Plate (31) and Rear End Plate
Assembly (30) o the hub of the Rotor.
Lift the Cylinder (33) from the Rotor.
Remove the Vanes (37) from the Rotor.
Support the Front End Plate Assembly (38), as near the rotor body
as possible, on the table of an arbor press and press the Rotor
from the Front Rotor Bearing (40). Remove the Bearing from the
Front End Plate.
Disassembly of the Housing
Use a wrench to unscrew and remove the Inlet Bushing
Assembly (27) from the Motor Housing Assembly (1). Remove the
Inlet Bushing Bezel (26) and the Wave Washer (25).
Pull the Housing Grip (21) o the Motor Housing.
Pull or carefully pry the Grip End Cap (23) o the inlet end of the
Grip and remove the two End Cap Muer Elements (24).
Pull the Grip Muer Element (22) out of the inlet end of the Grip
and the two Housing Muer Elements (20) out of the trigger end
of the Grip.
For Top Inlet Models, use a 3/16” hex wrench to unscrew and
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remove the Inlet Plug Assembly (15).
Using a 1/4” hex wrench, unscrew and remove the Rear Housing
Cap Assembly (9).
Remove the Throttle Valve Spring (19) and the Throttle Valve (18)
from the rear of the Housing.
If the Throttle Valve Seat (17) must be replaced, insert a hooked
tool through the central opening of the Seat and pull it from the
Motor Housing.
Use a #2 Phillips Head Screwdriver, to unscrew and remove the
Reverse Lever Screw (8) and lift the Reverse Lever (7) out of the
Motor Housing.
Insert a 5/16” wooden dowel between 6 and 8 inches long, into
the Rear Housing Cap opening and push the Reverse Valve Front
O-ring (6B), Reverse Valve Assembly (5) and Wave Washer (6A) out
the motor end of the Housing.
Use a hooked tool to pull the Housing O-ring (4) out of the Motor
Housing.
Use a 1/16” pin punch to drift the Trigger Retaining Pin (13) out
of the Motor Housing and pull the Trigger Assembly (11) out of
the Housing.
For Models having a memory chip, if the chip must be replaced,
pry the Memory Chip Holder Assembly (14) out of the Motor
Housing in the area above the trigger location.
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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 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.
Except for bearings, always clean every part and wipe every part
with a thin lm of oil before installation.
Apply O-ring lubricant to all O-rings before nal assembly.
Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in a clean, suitable cleaning solution
and dry with a clean cloth. Sealed or shielded bearings should
never be cleaned. Work grease into every open bearing before
installation.
Assembly of the Housing
For Models having a memory chip, if the Memory Chip Holder
Assembly (14) is being replaced, insert the memory chip into the
Holder with the contact ends leading. Position the Assembly at
the slot in the exterior wall of the Motor Housing (1) above the
trigger hole with the exposed contacts away from the Housing
and pointing toward the spindle end of the tool. Press the
Assembly into the slot.
Lubricate a new Trigger Shaft O-ring (12) and install it in the
groove on the shaft of the Trigger Assembly (11).
Insert the shaft of the Trigger Assembly into the hole in the Motor
Housing (1) until the at on the shaft is aligned with the hole in
the Housing for the Trigger Retaining Pin (13). Tap the pin into the
Housing to capture the Trigger Assembly.
Lubricate the Housing O-ring (4) with O-ring lubricant and install
it at the bottom of the cylinder bore in the Motor Housing.
Inspect the face on the hub of the Reverse Valve Assembly (5)
for nicks or damage. Replace the Assembly if damage is evident.
Examine the Reverse Valve Seals (6) and (6B) for nicks or cuts and
replace the Seals if damaged.
Lubricate the Reverse Valve Seals (6) and (6B) with O-ring lubricant.
Insert O-Ring (6B) over front end of Reverse Valve Assembly (5).
Insert Reverse Valve Assembly (5), small seal end and Wave
Washer (6A), and load into the cylinder bore of the Motor
Housing. Push the Assembly toward the bottom of the cylinder
and seat in its proper location making sure all Seals are correctly
positioned.
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Rotate the Valve inside the Housing until the threaded hole into the
side of the Valve for the Reverse Lever Screw (8) is centered radially
in the slot in the top of the Housing for the Reverse Lever (7).
Install the Reverse Lever in the slot and use a #2 Phillips Head
Screwdriver to secure the Lever to the Valve with the Reverse
Lever Screw.
Install the Throttle Valve Seat (17) in the bottom of the housing
cap opening. Use a rod with a at end and no sharp edges to push
the Seat at at the bottom face of the opening.
Install the Throttle Valve (18), at face leading, in the opening
against the Valve Seat. Place the Throttle Valve Spring (19), small
end leading, into the Housing against the Valve. Encircle the hub
on the Valve with the Spring opening.
Examine the Rear Housing Cap Seal (10) for nicks or cuts. If
damaged, carefully install a new Seal over the threads of the Rear
Housing Cap Assembly (9).
Using a 1/4” hex wrench, thread the Assembly into the rear of the
Motor Housing. Tighten the Assembly between 15 and 20 ft-lbs.
(20 and 27 Nm) torque.
For Top Inlet Models, examine the Inlet Plug Seal (16) for nicks or
cuts. If damaged, carefully install a new Seal over the threads of
the Inlet Plug Assembly (15).
For Top Inlet Models, use a 3/16” hex wrench to thread the
Assembly into the top of the Motor Housing. Tighten the
Assembly between 15 and 20 ft-lbs. (20 and 27 Nm) torque.
Lay a Housing Muer Element (20) on each side of the handle
rib and use a non-pointed probe to fully push the end of each
Element into the recess near the body of the Housing.
Install the Housing Grip (21) over the Elements and onto the inlet
end of the Motor Housing. Make certain the Grip is fully seated
against the Housing and the Trigger Assembly works freely.
Fold the Grip Muer Element (22) in half and then fold each half
equally again and insert it into the bottom of the Grip.
Stack the two End Cap Muer Elements (24) inside the Grip and
push the Grip End Cap (23) onto the inlet end of the Grip.
If the Inlet Screen (29) required replacement, use a wooden dowel
to carefully push a new one into the Inlet Bushing (27).
If the Inlet Bushing Seal (28) is nicked or damaged, carefully install
a new one over the threads of the Inlet Bushing.
Install the Inlet Bushing Bezel (26), small end leading, followed
by the Wave Washer (25) onto the threads of the Inlet Bushing
against the Seal.
Thread the assembled Inlet Bushing through the Grip End Cap
into the handle of the Motor Housing and tighten the Bushing
between 15 and 20 ft-lbs. (20 and 27 Nm) torque.
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