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ASSEMBLY
General Instructions
1. Always press on the inner ring of a ball–type bearing
when installing the bearing on a shaft.
2.
Always press on the outer ring of a ball–type bearing
when pressing the bearing into a bearing recess.
3.
Unless otherwise noted, always press on the stamped
end of a needle bearing when installing the needle
bearing in a recess.
4.
Whenever grasping a tool or part in a vise, always use
leather–covered or copper–covered vise jaws. Take
extra care with threaded parts and housings.
5.
Always clean every part and wipe every part with a
thin film of oil before installation.
6.
Apply a film of O–ring lubricant to all O–rings before
final assembly.
7.
Check every bearing for roughness. If an open
bearing must be cleaned, wash it thoroughly in a
suitable cleaning solution and dry with a clean cloth.
Sealed or shielded bearings should never be
cleaned. Work grease thoroughly into every open
bearing before installation.
Assembly of the Piston Housing
1. Replace the Adjusting Screw Assembly (47), Bevel
Gear Bearing (46), and the Bevel Gear Assembly
(43). If the Eccentric (44) was removed from the
Bevel Gear, rivet it back onto the Bevel Gear.
2. Place a new Rear Piston Guide, channel up, tab to the
rear, in the channel of the Piston Housing.
3. If required, place a new Connecting Rod Bearing
(51), Spring Washer (55), Washers (54), and Grease
Seals (53) onto the Piston Assembly (49).
4. Place the Piston Assembly into the Piston Guide with
the Connecting Rod Bearing going over the Pivot Pin
(45) in the Eccentric and the Washer/ Seal pack going
into the slot in the channel.
5. Put the other Rear Piston Guide (57) and the Front
Piston Guide (56) over the Piston Assembly.
6. Carefully install the Piston Housing Cover (58) and
secure it with four Housing Cover Cap Screws (61).
7. If required, reinstall the Saw Guide (59) with four
Saw Guide Screws (60).
Assembly of the Throttle Mechanism
1. Clamp the Motor Housing Assembly (1) in
leather–covered or copper–covered vise jaws, Exhaust
Deflector Assembly (16) end up.
2. Reinstall the Exhaust Deflector Adapter (13) into the
Motor Housing Assembly (1). Place the Exhaust
Deflector Screen (17) inside the Exhaust Silencer (18)
MAINTENANCE SECTION
and the Exhaust Silencer inside the Exhaust Deflector
Assembly (16).
3.
Secure the Exhaust Deflector Assembly to the
Exhaust Deflector Adapter with the two Exhaust
Deflector Retaining Pins (15).
4.
If required, reinstall the Trigger (2):
a. Place the Latch Release Pin (12D) through the slot
b. Secure the Latch (12A) and Latch Spring (12C) to
c. Place the Trigger Spring (3) through the trigger
d. Carefully place the Trigger into the trigger slot
5.
Place the Throttle Valve Plunger (12), small end last,
through the Throttle Valve Bushing bore and into the
handle until it contacts the Trigger.
6.
Secure the Throttle Valve Plunger with the Throttle
Valve Bushing Assembly (6).
7.
If required, reinstall the Throttle Valve Seat (8A), the
Valve Ball (8), and the Throttle Valve Spring (9).
Secure these parts with the Throttle Valve Spring Seat
(10) and the Air Strainer Screen (11).
Assembly of the Motor Assembly
1.
Place the Rear Rotor Bearing (25) into the Rear End
Plate.
2.
Place the Bevel Pinion Rear Bearing (39) and the
Front Rotor Bearing (32) into the Front End Plate.
3.
Press the Rear End Plate (26) onto the Rotor.
4.
Replace the Cylinder (27). Replace the Vanes (29).
5.
Carefully press the Front End Plate (31) onto the
Rotor (28).
6.
Replace the Cylinder Dowel (30).
Assembly of the Motor Housing Assembly
1.
Press the Locking Screw Cap (21) into the Motor
Housing Assembly (1).
2.
Install the Motor Seat Pin (24) in the Motor Housing.
3.
Carefully install the Motor Seat Assembly (22) into
the motor bore making sure that the Motor Seat Pin
(24) goes into the hole in the Motor Seat.
4.
Carefully install the assembled motor, splined end
trailing, making sure that the motor doesn't jamb in
the bore.
5.
Place the Motor Spacer (33) over the splined end of
the motor
6.
Secure the Motor with the Motor Lock Plate (34),
Lock Plate Support (35), and four Support Screw
Lock Washers (37) and Lock Plate Support Screws
(36).
17
in the handle for the Trigger and secure it with the
Release Pin Button (12E).
the Trigger with the Latch Pin (12B).
slot and into the spring recess.
and secure it with the Trigger Pin (4).
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