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SERVICE INSTRUCTIONS
MOTOR SERVICING
1. Remove the 2 nuts (51) and then lift off the chain guard
(50).
2. Lift off the bar (61) and chain (73). If it is necessary to
take tension off the bar and chain, turn the screw (68)
counter clockwise.
For Diamond Saws with Serial Number 357 and above,
follow the steps a thru c, then proceed to Step 7.
a. Remove the e-clip (60) and slide off items 48, 49 and 58.
b. Remove the retaining ring (100) and then spacer (47).
c. Remove the retaining ring (98) and then items 93 thru
96.
For Diamond Saws with Serial Number 356 and below,
follow the steps below.
3. Slide the sprocket wrench (84) over the sprocket (48).
While gripping the sprocket wrench and using an open end
wrench, turn the hex head on the Trantorque™ adapter cap
(49) counter clockwise until the Trantorque™ adapter can
be removed from the motor shaft (53).
4. Remove the spacer (47), support washer (100), and
o-ring (97).
5. Remove the retaining ring (98).
6. Remove the capscrews (1).
7. Using a fl at-blade screwdriver or similar tool, gently pry
the gear housing (4) away from the valve handle (22). Lift
the gear housing straight up. Do Not tilt the housing or pry
on the fl at surface inside of the surrounding groove. For
prying, only use the groove provided at the split between
the parts to prevent scratches on the inner mating surfaces.
8. Remove the two gears (9 & 13), needle roller (54), and
the idler shaft (8).
9. Remove the large face seal o-ring (7) while being care-
ful not to damage the o-ring groove or surrounding surface.
10. While protecting the motor surface of the valve handle
from damage, tap lightly on the small diameter end (gear
side) of the motor shaft to remove it and the seal washer
(94), seal ring (96), v-ring seal (95), o-ring (93), and bear-
ing (92) from the front of the valve handle. Remove the seal
keeper, seal spacer, seal, and o-ring from the motor shaft.
11. To remove the bearing from the shaft, press on the out-
side end (sprocket end) of the motor shaft while supporting
the outer race of the bearing. Discard the old bearing.
12. Remove the retaining ring (91) at the bottom of the
bearing bore. Remove the seal backup washer (57). Re-
move the quad ring (90) and o-ring (56) using the appropri-
ate o-ring service tools. Discard the quad ring and o-ring
13. The bushings (6) can be removed using p/n 11930 col-
let from p/n 05064 bearing puller kit.
MOTOR INSPECTION AND
CLEANING
Inspect and clean all parts as follows:
CLEANING
Clean all parts with a degreasing solvent. Blow dry with
compressed air and wipe clean. Use only lint-free cloths.
GEAR HOUSING
The chamber bores and bottoms around the shaft bushings
should be polished and not rough or grooved. If the bush-
ing bores are yellow-bronze, replace them and investigate
the cause of wear.
The fl at surfaces around the chamber and bolt holes should
be fl at and free of nicks or burrs that could cause misalign-
ment or leaks.
BUSHINGS
The inside of the bushings should be gray with
some bronze showing through. If signifi cant yellow-bronze
shows, replace the bushings. Inspect motor shaft for cor-
responding wear and replace as required.
GEARS
The drive and idler gears should have straight tips without
nicks, square tooth ends and a smooth even polish on the
teeth and end faces. Check for cracks between the drive
gear keyway and gear tooth root. Replace the gear if
cracks are present.
VALVE HANDLE MOTOR SURFACE
The surface near the gears should show two interconnect-
ing polished circles without a step. The bottom of the o-ring