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P 7440 Edition 10 37
20. Using needle nose pliers, insert the Throttle Valve
(13), long stem leading, into the opening against the
Seat. Center the Valve in the Seat.
21. Install the Throttle Valve Spring (14) in the opening
so that it encircles the Valve.
22. The Exhaust Diffuser (15) has one slot that is longer
than the other five slots. The Back Cap has a short,
molded stud projecting from the inlet end. Place the
Exhaust Diffuser against the Back Cap with the long
slot encircling the molded stud. Rotate the Diffuser
counterclockwise until the wall of the slot stops
against the stud. The exhaust ports are now in the full
open position which will provide maximum free speed.
23. If the Inlet Screen (18) required replacement, use a
wooden dowel to carefully push a new one into the
Inlet Bushing (16).
24. If the Inlet Bushing Seal (17) is nicked or damaged,
carefully install a new one over the threads of the Inlet
Bushing.
25. Thread the Inlet Bushing Assembly through the Dif-
fuser and Back Cap into the Motor Housing. Using a
1-3/16” wrench on the flats of the Back Cap to keep it
from turning, tighten the Inlet Bushing between 15
and 20 ft-lbs. (20 and 27 Nm) torque.
26. The Throttle Plunger ( 5) has a lengthwise flat on the
outer edge at one end of the Plunger. Insert the
Plunger, flat end first, into the cross hole in the Hous-
ing. Push on the end of the Plunger to make certain it
springs back from contact with the stem of the Throt-
tle Valve.
27. Position the Throttle Lever (10) in the slot in the Back
Cap and Motor Housing and using a 1/16” diameter
rod, align the holes through the Back Cap, Motor
Housing and Throttle Lever. While maintaining align-
ment, install the Throttle Lever Pin (11) in place of
the rod by tapping it through all three pieces.
28. Remove the tool from the vise jaws and install the
Housing Grip (93) over the Clutch Housing.
29. Install the Grip Retaining Ring (96) in the external
groove on the Clutch Housing ahead of the Grip to
retain the Grip on the Housing.
30. For Models with Quick Release Bit Holders, place the
Bit Retaining Ball (85) in the hole through the wall of
the Bit Holder and slide the Bit Retaining Sleeve (88),
large end trailing, onto the Bit Holder. Slide the
Retaining Sleeve Spring (89) and Spring Seat (90)
onto the Bit Holder and secure the components by
installing the Retaining Ring (91) in the external
groove at the output end of the Bit Holder.
The thread in the following step is a left-hand thread.
Rotate the component counterclockwise to tighten it.
31. Thread the Clutch Adjusting Hole Cover (97) onto
the Clutch Housing against the Housing Grip and
hand tighten it between 2 and 6 ft-lbs. (3 and 8 Nm)
torque.
The following step has parts with a left-hand thread.
Rotate the components counterclockwise to tighten them.
32. Thread the Non-Rotating Bit Finder (92) or Clutch
Housing Cap (98) onto the Clutch Housing and hand
tighten it between 2 and 6 ft-lbs. (3 and 8 Nm) torque.
TESTING THE TOOL
Before placing the tool back in service, test the tool in a
run down application to determine if adjustments are
necessary to satisfactorily perform the operation. Since five
interrelated adjustments can affect tool performance, only
experience, along with trial and error, can dictate which
adjustment or combination of adjustments will provide the
desired results.
The Clutch Spring (59 or 75), the clutch adjustment
procedure, the exhaust flow, the length of the Push Rod
(34) and the length of the Shutoff Valve (20) can
individually or collectively have an effect on torque and/or
speed. Always try to make adjustments before replacing or
attempting to modify components. If adjustments are
unable to provide the desired torque, it may be necessary
to install a lighter or heavier Clutch Spring.
If the tool ratchets when operated but fails to shutoff, it
may be necessary to shorten the Push Rod. Only shorten
the Push Rod in small increments. Increments between
0.005” and 0.010” (0.13 and 0.25 mm) are recommended. If
the tool stalls and does not shutoff, runs slower than
normal or has low power, the Shutoff Valve may require
lengthening. To lengthen the Shutoff Valve, grasp the stem
between two pieces of rubber or other non-slip, non-
marring material and rotate the molded nut
counterclockwise. Rotating the nut one half revolution will
lengthen the Valve approximately 0.009” (0.23 mm).
Should the stem of the Valve become bent, marred, nicked
or damaged in any way during the adjustment process,
replace it.
MAINTENANCE (Continued)