4

DISASSEMBLY/ASSEMBLY INSTRUCTIONS

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 t o ‘‘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 t o ‘‘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 assembly
(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 assembly (64) and compo-
nents as described in ‘‘PISTON SECTION”.
_Remove three cap screws (47), releasing piston stop (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 piston stop (46) to frame assembly (tangs on mag-
net facing away from frame) and secure with three cap screws
(47). TIGHTEN TO 45–50 IN/LBS.
_Assemble outer sleeve assembly (64) and components to tool
as described in ‘‘PISTON SECTION”.