Reassembly

Service

1.Clean all the parts carefully in a compatible solvent, and inspect for wear or damage. Use all the repair kit parts during reassembly, and replace other parts as needed.

2.Check the polished surfaces of the piston (2), dis- placement rod (8), and cylinder (17) wall for scratches or wear. A scored rod causes premature throat seal wear and leaking.

3.Lubricate all parts with a light, water-resistant grease.

4.Clamp the displacement rod (8) upright in the vise by closing the vise jaws on the flats of the displace- ment rod.

5.Pull the exhaust valve poppets (16) into the value actuator (13), and clip off the top part shown with dotted lines in FIG. 4.

6.Install the new grommets (12) in the actuator (22), place the inlet valve poppets (1) in the piston, and thread the bottom valve nuts (30) onto the stems of the inlet valve poppets until there are a few threads left before the threads run out.

NOTE: If you thread the valve nuts too far down onto the poppets, they will run off of the threaded part of the pop- pets.

7.Grease heavily and place the trip rod (11) in the air motor piston (2), place the actuator (13) in the yoke (22), and place the well-greased actuator/yoke assembly in the piston with the trip rod going through the center holes of the actuator and yoke and the stems of the inlet valve poppets (1) going through the grommets (12).

8.Thread the top of valve nuts (30) onto the stems of the inlet valve poppets (1) until one thread of the inlet valve poppets is exposed above the valve nuts.

9.Install the pins (23) in the yoke (22), place the toggle arm (25) ends of the toggle assembly (M) onto the toggle pins, and snap the pivot pin (26) ends of the toggle assembly into the piston lugs (L).

10.Measuring with the gauge create 0.145 inch (3.7 mm) of clearance between the inlet valve poppets

(1) and the piston seat when the inlet valve is open. See the Cutaway View, FIG. 4.

NOTE: Adjust the distance between the inlet valve pop- pets and the piston seat by turning the top valve nuts (30).

11.Tighten the bottom valve nuts (30) by hand. The grommets (12) should be slightly compressed.

12.Align the holes in the valve nuts (30) and the slots on the stems of the inlet valve poppets (1), and drop the lock wires (31) through the holes in the valve nuts and into the slots in the stems of the inlet valve poppets. Pull the lock wires down tightly, and bend the ends with pliers so that they cannot be pulled back out of the holes.

NOTICE

Never re-use the old lock wires. They will get brittle and break easily from too much bending.

13.Take the assembly out of the vise so that you can move it around for the next two steps.

14.Grease and install the new o-rings (9, 24, 112).

15.Install the new u-cup packing (6) through the bottom of the air motor base, with the lips facing toward the bottom of the pump.

16.Slide the displacement rod (8) down through the packings, and lower the air motor piston (2) into the air motor base (5).

17.Clamp the air motor upright in the vise by closing the vise jaws below the flange.

18.Carefully lower the air motor cylinder (17) straight down onto the piston assembly (2). Tighten the six screws (21) holding the air motor cylinder to the air motor base (5).

NOTICE

To avoid damaging the cylinder wall, lower the cylin- der straight down onto the piston. Never tilt the cylin- der as it is being lowered.

19.Pull the trip rod (11) so it is sticking up out of the air motor cylinder (17).

NOTE: You may have to hold the unit upside down to shake the trip rod loose.

306518ZAC