DISASSEMBLY/ASSEMBLY INSTRUCTIONS
_ Assemble cover (2) to housing, securing with four screws (1).
PULLEY SPINDLE SECTION DISASSEMBLY
_ Follow instructions for disassembly of BELT AND PULLEY SECTION and remove belt (3) and pulley (12).
_ Remove four cap screws (20) and separate drive housing (10) from frame assembly (35). NOTE: Housings will have to be pulled apart approximately 11” (279 mm) to completely sepa- rate pulley spindle (23) from frame assembly (35).
_ Using a spanner type wrench, unthread and remove lock screw (25).
_ Pull spindle (23) and components from housing (10).
_ NOTE: Bearings (21) are press fit on spindle (23). Do not re- move unless it should become necessary to replace, as Brin- elling of the bearing races may occur, making replacement necessary.
PULLEY SPINDLE SECTION ASSEMBLY
_ Assemble felt seal (24) to lock screw (25).
_ Assemble bearing (21) to ‘‘pulley” end of spindle (23), press- ing on inner race of bearing.
_ Assemble spindle (23) and bearing into housing (10), press- ing on outer race of bearing.
_ Assemble bearing spacer (22) and bearing (21) onto spindle, pressing on inner race of bearing.
_ Assemble lock screw (25) to housing (10), securing spindle and components.
_ Apply approximately 1/4 oz. (7 g) of ARO 33153 grease to in- ternal splines of spindle (23) and assemble housing (10) and components to frame assembly (35), securing with four cap screws (20).
_ Refer to ‘‘BELT AND PULLEY SECTION” to complete the as- sembly procedure.
PISTON SECTION DISASSEMBLY
_ Loosen upper cap screw (28) on yoke assembly (27) to allow for removal of quill (55).
_ Using a strap type wrench, unthread and remove outer sleeve assembly (64) and components from the tool. NOTE: Remove sleeve (64) with care. Pull sleeve straight away from the tool so as not to bend the piston cylinder (63), damaging the inside diameter.
_ Remove spindle nut (62) and locknut (68).
_ Remove spindle (58), bearing stop (60), bearings (59), spacer (57) and bearing (56) from quill (55).
_ Remove quill (55) and piston cylinder (63) from sleeve. NOTE: Handle the piston cylinder carefully to prevent damaging or distorting the inside diameter.
_ Remove piston cylinder (63) from quill (55).
_ Remove seal (50) and unthread and remove plate nut (51), re- leasing plate (52) and spring washer (53).
_ Do not remove wiper (26) from groove in frame assembly (35), unless damage is evident. To remove wiper (26), refer to ‘‘Pulley Spindle Section” to separate drive housing (10) from frame assembly (35).
_ Remove two cap screws (32), releasing stabilizer rod (31) and yoke assembly (27) from tool. Wiper (26) can now be re- moved.
PISTON SECTION ASSEMBLY
_ Grease wiper (26) with ARO 36460 lube and assemble to groove in frame assembly (35). NOTE: Assemble wiper with lips towards ‘‘chuck” end of tool.
_ Assemble yoke assembly (27) to stabilizer rod (31) and as- semble stabilizer rod to frame assembly (35), securing with two cap screws (32).
_ Refer to ‘‘Pulley Spindle Section” to assemble housing (10) to frame assembly (35).
_ Grease wiper (67) with ARO 36460 lube and assemble to groove in front bushing of outer sleeve assembly (64), with lips of wiper facing towards sleeve (64).
_ Grease wipers (54) with ARO 36460 lube and assemble to grooves in quill (55), with lips of wipers facing away from each other.
_ Assemble spring washer (53) and plate (52) to quill (55), se- curing with plate nut (51).
_ Assemble square seal (50) to quill (55).
_ Assemble bearing (56) to spindle (58), pressing on inner race of bearing.
_ Assemble spindle (58) and spacer (57) into quill (55).
_ Pack bearings (59) with ARO 33153 grease and assemble onto spindle (58) and into quill (55). NOTE: Assemble bear- ings with open faces together (shielded sides facing out).
_ Assemble wiper (61) to groove in bearing stop (60), assem- bling with lip of wiper toward the ‘‘chuck” end of the tool.
_ Assemble bearing stop (60) into quill (55).
_ Assemble spindle nut (62) to spindle and tighten securely. _ Lubricate i.d. of piston cylinder (63) and o.d. of quill (55) with
ARO 36460 lube and assemble into outer sleeve (64). Handle piston cylinder with care so as not to damage or distort the i.d.
_ Assemble locknut (68) to quill (55) and tighten securely.
_ Grease ‘‘O” rings (48 and 49) with ARO 36460 lube and as- semble to grooves in frame assembly (35).
_ Assemble outer sleeve assembly (64) and components to frame assembly (35), assembling quill (55) thru yoke assem- bly (27). Tighten outer sleeve securely. NOTE: Use caution when inserting quill (55) thru frame assembly so as not to damage wiper (26).
_ Tighten upper cap screw (28), securing yoke assembly.
VALVE HOUSING SECTION DISASSEMBLY
_ Control valves (37 and 39), manifold assembly (77) and con- trol assembly (93) can be serviced without disrupting any oth- er section of the tool.
_ Remove set screws (36 and 40), releasing control valves (37 and 39).
_ To service bushing assembly (45), pin (44), stem (43) or spring (42), remove outer sleeve (64) and components as de- scribed in ‘‘PISTON SECTION”.
_ Remove three cap screws (47), releasing magnet (46).
_ Remove bushing assembly (45), pin (44), stem (43) and spring (42).
_ See pages 8 and 9 for disassembly and assembly of manifold assembly (77) and control assembly (93).
VALVE HOUSING SECTION ASSEMBLY
_ Lubricate all ‘‘O” rings with ARO 36460 lube when assem- bling.
_ Assemble control valves (37 and 39) to frame assembly (35), securing with set screws (36 and 40). Set screws must be air tight.
_ Assemble spring (42) to stem (43) and assemble into frame assembly.
_ Assemble pin (44) into bushing assembly (45) and assemble into frame assembly.
_ Assemble magnet (46) to frame assembly (tangs on magnet facing away from frame) and secure with three cap screws (47). TIGHTEN TO
_ Assemble outer sleeve (64) and components to tool as de- scribed in ‘‘PISTON SECTION”.
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