Repair
308485R 13
9. Pull the piston assembly from the air motor base
(28) and set it aside.
10. Remove the pump seal (10†) with a pick, and clean
the groove in the air motor base (28). Remove any
dirt from the groove and wipe the groove clean with
a cloth.
11. Inspect the air motor for damaged or worn inlet
valve grommets (17*), o-rings (19*, 20*), valve nuts
(21*), lock wires (22*), exhaust valve poppets (26*),
or inlet valve poppets (32*).
If any of these parts need to be replaced, continue
with the remaining Disassembly steps. Otherwise,
go to Reassembly, page 14.
12. Using a screwdriver, push down on the trip rod
yoke (13), and snap the toggles down (F
IG. 4).
13. For this step, while prying with the screwdriver with
one hand, cover the toggle assemblies with the
other hand to catch the spring-loaded toggle
assemblies as they snap out of the lugs. Place the
tip of the screwdriver into the piston between the
piston lugs (L) below the pivot pins (16) on the
toggles, pry up using the screwdriver handle to
compress the springs on the toggle assembly (M)
up and away from the piston lugs, and remove the
parts (F
IG. 4).
14. Straighten the lock wires (22*) and remove them
from the valve nuts (21*). Screw the top nuts off.
Remove the trip rod yoke (13), actuator (12), and
trip rod (31). Unscrew the bottom nuts (21*) and
remove the poppets. Make sure the valve bar
spring clips (14) are not worn or damaged, and that
they properly guide the actuator (12).
15. Remove the exhaust valve poppets (26) by cutting
them with a side cutter, then pull them out of the
actuator (12).
16. Clean all of the parts carefully in a compatible
solvent and inspect them for wear or damage. Use
all of the repair kit parts during reassembly, and
replace other parts as necessary.
17. Check the surfaces of the piston, piston rod, and
cylinder wall for scratches or wear. A scored rod
will cause premature packing wear and leaking.
18. Lubricate all of the parts with a light, waterproof
grease.
To reduce the risk of pinching or amputation of
fingers, keep fingers clear of the toggle assemblies
when snapping the toggles (M in FIG. 4) up or down.
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