Service
10 306518ZAC
Reassembly
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 F
IG. 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, F
IG. 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.
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).
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.
NOTICE
Never re-use the old lock wires. They will get brittle
and break easily from too much bending.
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.
