c. (Fig. 9-4) Assemble all four pistons. Put con-
necting rod (25h) into piston (25g) and line up hol-
es. Slide piston pin (25b) thru holes in piston (25g)
and connecting rod (25h). Press a piston pin plug
(25a) into each side of piston (25g) over piston pin
(25b). Install rings (25c) onto piston (25g).
(1) Put oil ring (25f on first.
(2) Install compression ring (25e) next, make
sure square groove is facing down.
(3) Install two compression rings (25d), make
sure beveled edge is facing up.
d. (Fig. 9-1) Bolt each connecting rod (9) to
crankshaft (49). Insert piston wire (23) into each
bolt (24). Rotate crankshaft until two pistons on one
side are about even height. Install new gasket (22),
slide cylinder (21) over both pistons (25), Fasten in
place with four washers (20) and four nuts (19).
Tighten to 250 in lbs (44,650 gr cm) when pistons
(25) are attached check end play between con-
necting rods and crankshaft. Acceptable mea-
surement is less than 0.015 in (0.038 cm).
e. Assemble both valve assemblies (17). (Fig. 9-
3) Take top plate (17e) which is marked this side
up and fasten both intake valves (17c) in place
with four screws (17b). Intake valves (17c) are
0.010 in (0.025 cm) thick. Fasten both discharge
valves (17i) to bottom plate (17j) with four screws
(17h), Discharge valves (17i) are 0.015 in (0.038 cm)
thick. Place gasket (17f) over bottom plate assem-
bly (17g) and place top plate assembly (17a) over
gasket (17f) lining up holes. Insert both roll pins
(17d) thru holes and tap in place with a soft drift or
i. Set pulsation chamber (4) in place between
both heads (15), make sure O-Ring (14) is in place in
each head (15). Screw four bolts (3) down tight to a
torque of 350 in lbs (62,510 gr cm). Tighten six head
bolts (10 and 13) in each head to 250 in lbs (44,650
gr cm). Tighten six head bolts (10 and 13) in each
head to 250 in lbs (44,650 gr cm) torque, doing the
two long bolts (10) first and the four short bolts (13)
last. After five hours use, retorque all head bolts (10
and 13) to 250 in lbs (44,650 gr cm).
j. Fill to proper level with oil, see Lubrication
Order in Chapter 3.
k. Rotate pulley (28) by hand a slight resistance
should be felt, but the pulley should move without
undue strain or binding.
l. Reinstall on cart. See instructions in Chapter
f. (Fig. 9-1) Place gasket (18), valve assembly
(17), and gasket (16) over cylinder (21), line up all
holes. Place head (15) over gasket (16) and fasten
with two long bolts (10) and four short bolts (13);
snug only, not tight.
g. (Fig. 9-2) Place twosprings (12h) and two pins
(12g) into each head (Fig. 9-1, 15). Place two O-
Rings (12f) over each of the four pistons (12e) and
insert the pistons (12e) into both bodies (12d). Posi-
tion both bodies (12d) on each head (Fig. 9-1, 15);
place a gasket (12c) and a cover (12b) over each
body (12d) and fasten allparts with five bolts (12a).
h. Fig 9-1) Place screen (9), inner filter (8),
outer filter (7) and filter retainer (6) on the outside
of each head (15). Fasten with three screws (5).