JARVIS · noticetoemployer and safety director Model MCS 300 page 2 of 16 JARVIS® 6201010:. PRODUCTS CORPORATION 33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457--4926 UNITED STATES

TABLE OFCONTENTS Page. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model MCS 3009 inch Blade 4001044. . . . . . . . . . . . . . . . . .9 inch Blade with Depth Gage 4001050. .9 inch Blade Dual Triggers 115V 400106610.5 inch Blade 4001042. . . . . . . . . . . . . .10.5 in. Blade Dual Triggers 115V 400106710.5 in. Blade Dual Triggers 220V 400107012 inch Blade 4001045. . . . . . . . . . . . . . . .12 inch Blade Dual Triggers 115V 4001065

Balancer 4042040. . . . . . . . . . . . . . . . . . . . . .Air Filter/Regulator/Lubricator 3022003. . . .Air Supply Hose Assembly 1059015. . . . . .

Model MCS 300Air Circular Saw

EQUIPMENTSELECTION Ordering No.. . . . . . . . . .

• Notice to Employer and SafetyDirector 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

• Notice to Operators, Maintenanceand Cleanup Personnel 3. . . . . . . . . . . . . .

• Parts Diagram and List 4. . . . . . . . . . . . . .• Special Tools 8. . . . . . . . . . . . . . . . . . . . . . .• Specifications 9. . . . . . . . . . . . . . . . . . . . . .• Installation Instructions 9. . . . . . . . . . . . . .• Operation Instructions 9. . . . . . . . . . . . . . .• Maintenance Instructions 10. . . . . . . . . . .

®JARVIS6201010:.

PRODUCTS CORPORATION33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457--4926

UNITED STATES OF AMERICA E--MAIL. [email protected]

TEL. 860--347--7271 FAX. 860--347--6978 WWW. jarvisproducts.com

notice to employerand safety director

Model MCS 300 page 2 of 16

®JARVIS6201010:.




1 Remove and repair any tool that malfunctions. All personnel must be instructed to remove anymalfunctioning equipment.

2 Ensure that all employees who use this tool are trained in the proper use of this tool and are awareof the dangers that may arise if they do not follow the procedures outlined in this brochure.

3 Enclosed are four (4) copies of “NOTICE TO OPERATORS, MAINTENANCE AND CLEANUPPERSONNEL.” Post one copy on the employees’ bulletin board; give one copy to operator(s); giveone copy to themaintenance foreman; andgive one copy to the sub-contract cleanup / internal cleanupforeman. Additional copies will be provided upon request.

4 The tool is designed and intended to be powerful. This fact should be obvious to your employees,but you must emphasize it to them.

5 Never make modifications or alterations to the tool. Replace any missing or illegible labels.6 Ensure that proper procedures are established in accordancewithOSHA’s lockout/tagout procedures

(29 CFR 1910.147) to prevent accidental startup or release of stored energy.7 Hand/Wrist/Arm injury and other Cumulative Trauma Disorders may result from repetitive work,

motion or vibration. You must make your employees aware of hazards, symptoms of injury and ap-propriate prevention. See OSHA’s “Ergonomics ProgramManagement Guidelines for MeatpackingPlants.”

8 Follow our installation and maintenance instructions for proper installation and care of the tool.9 Ensure that employees wear eye protection in accordance with OSHA’s eye and face protection re-

quirements (29 CFR 1910.133) when operating the tool.10 Avoid injury. Do not permit the tool to be misused.11 Ifyou resellordistribute a Jarvis product, youmust provide the purchaserwith the appropriate safety

sheets and tool brochure. Additional copies of safety sheets and tool brochures will be provided uponrequest.

NOTICE TO EMPLOYER AND SAFETY DIRECTORAVOID INJURY

Keep hands clear.

notice to operators, maintenanceand cleanup personnel

Model MCS 300page 3 of 16

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1 Disconnect the air hose in accordance with OSHA’s lockout/tagout procedures (29 CFR 1910.147)before making any blade changes.

2 Disconnect the air hose in accordance with OSHA’s lockout/tagout procedures (29 CFR 1910.147)before performing any repairs or maintenance.

3 Disconnect the air hose -- or have the air hose disconnected -- in accordancewithOSHA’s lockout/tag-out procedures (29 CFR 1910.147) before performing any cleanup.

4 Disconnect the air hose when the tool is not in use.5 Never put fingers, hands or other parts of the body on the cutting edge or within the cutting path of

the tool when it is connected to an air supply.6 Test the tool prior to use or daily. For single trigger tools: Depress the trigger and the tool should

start; release the trigger and the tool should stop. For dual trigger tools: Depress one trigger, thenpause one second and depress the other trigger and the tool should not start. Repeat this procedurereversing the triggers. Depress both triggers simultaneously and the tool should start. With the toolrunning, release one trigger and the tool should stop. Continue holding the depressed trigger and thendepress the other trigger. The tool should not start. Repeat this procedure holding the other trigger.If the tool malfunctions, remove it from service and report or repair it immediately.

7 Never depress the trigger unless you want to use or test the tool.8 Never make modifications or alterations to the tool. Replace any missing or illegible labels.9 Always wear eye protection in accordance with OSHA’s eye and face protection requirements (29

CFR 1910.133) when using the tool.10 Always use both hands when starting and operating the tool to avoid the risk of possible “kick back”

or “recoil.” Continue holding the tool with both hands until the saw blade comes to a complete stop.

NOTICE TO OPERATORS, MAINTENANCE AND CLEANUP PERSONNELREMOVE ANY MALFUNCTIONING TOOL FROM SERVICE

REPORT ANY PROBLEMS TO YOUR SUPERVISOR

Keep hands clear.

parts diagram and listModel MCS 300 page 4 of 16

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1 1018128D Locking Lever 12 1054134D Depth Gage Screw 13 1032359D Depth Gage Plate 14 1007341Y Blade Nut 15 1023102 Blade, 9 inch 1

1023111 Blade, 10.5 inch, 84 teeth1023112 Blade, 12 inch1023575 Blade, 180 mm

6 1024217 Blade Guard, 9 inch 11024218 Blade Guard, 10.5 inch1024219 Blade Guard, 12 inch1024290 Blade Guard, 180 mm

7 1004314 External Tooth Washer 18 1055802* Hex Head Screw, 20 mm lg. 1

1055610 Hex Head Screw, 25 mm lg. 19 1019200 Auxiliary Handle 110 1010460 Dowel Pin 211 1035451 O--ring 112 1035565 U--cup Seal 113 1026205 Spur Gear (36 Tooth) 114 1010463 Spur Gear Pin 115 1021155 Ball Bearing 216 1013232 Retaining Ring 217 1035210 O--ring 218 1016560 Spur Gear Hsg, Roller Brgs 1

1016634 Spur Gear Hsg, Ball Brgs19 1038027 Grease Fitting 220 1007343 Spur Gear Hex Nut, LH Thd. 121 1007342* Crown Gear Hex Nut 122 1004411 Flanged Washer 123 1007380 Crown Gear Hex Nut 224 1035005 O--ring 125 1013275 Spiral Retaining Ring 126 1036264 Hanger Bushing 127 1042415 Hanger 128 1021352 Needle Bearing 1

ITEM PART NO. PART NAME QTY29 1004231 Lock Washer 230 1055613 Hex Head Screw 131 1055067 Socket Head Cap Screw 432 1030074 Key 133 1021415 Ball Bearing (Double Row) 134 1013273 Retaining Ring 135 1031030 Planetary Gear Hub 136 1004362 Pinion Gear Washer 137 1055852 Flat Head Socket Screw 138 1013276 Retaining Ring 339 1026204 Planet Gear 340 1021414G Needle Bearing 341 1010462 Planetary Gear Pin 342 1009127 Needle Bearing Inner Race 143 1026208 Pinion Gear 144 1026209 Planetary Ring Gear 145 1016563 Planetary Housing 146 3069002* Shim Package 147 1021278* Tapered Bearing Cone 248 1021413*G Tapered Bearing Cup 249 1026207* Crown Gear 150 1026206 Spur Gear (37 Tooth) 151 1030075 Key 252 1013274 Retaining Ring 153 1029355* Bearing Spacer 154 1010461* Crown Gear Pin 155 1055058 Flat Head Slotted Screw 656 1010509 Crown Gear Pin 157 1026243 Crown Gear 158 1029415 Flanged Spacer 1

3016507 Gear Hsg Assy, Ball Brgs(incls items 11--20, 22, 23, 28,32, 33, 42, 43 and 56--58)

3016508* Gear Hsg Assy, Roller Brgs(incls items 11--21, 28, 32, 33,42, 43 and 46--54)

ITEM PART NO. PART NAME QTY

Figure A

Y

Y A Jarvis special tool is available for disassembly andassembly. See Figure E on page 8 for part number.

G A Jarvis special tool is available for disassembly.See Figure E on page 6 for part number.

* Not used in current tools** Shim package contains 5 shims 0.1 mm thick and 5

shims 0.2 mm thick. Install only as many shims asnecessary to obtain proper fit.

D Used in 4001050 only

DD

D

*

G

*

**

*

parts diagram and listModel MCS 300page 5 of 16

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59 1035501 O--ring 160 1016561 Motor Housing (incl. item 61) 161 1017083 Danger Label 162 1021306 Ball Bearing 263 1014173 Wave Spring 164 1032530 Front Motor Plate 165 1064069 Rotor, 4 Vanes

1064044* Rotor, 5 Vanes 166 1040018 Vane for 4 Vane Rotor

1040017* Vane for 5 Vane Rotor 567 1029354 Rotor Spacer 268 1009157 Air Motor Sleeve 169 1054170 Rotor Screw 170 1035568 O--ring 171 1010373 Dowel Pin 172 1036261 Bushing 173 1018154 Trigger with items 71 and 72 174 1019201 Handle and Valve Housing 1

(includes items 94)75 1012110 Hose Clamp 276 1004230 Lock Washer 477 1055059 Cheese Head Screw 478 1051025 Quick Connect Plug 179 1051029 Quick Connect Socket 180 1059015 Hose Assy (includes item 79) 181 1051179 Muffler 182 1061802 Tubing 3 ft83 1017400 Name Plate and Info Label 184 1055274 Drive Screw 485 1054169 Valve Plug 186 1035162 O--ring 187 1014172 Compression Spring 188 1054178 Valve Screw & Spring Guide 189 1035244 O--ring 190 1016576 Seal Housing 191 1035575 Valve Seal 192 1013277 External Retaining Ring 193 1039069 Valve Plunger 1


Figure B

94 1036262 Bushing 295 1051180 Exhaust Pipe Fitting 196 1010355 Threaded Pin 197 1035287 O--ring 198 1032531 Rear Motor Plate 199 1010459 Dowel Pin 2

3016393 Motor Assembly (includesitems 62--69, 98 and 99)

3019222 Handle Assembly (includesitems 71--74 and 83--96)

3022085 Valve Plunger Assembly(includes items 88--93)


* not used in current tools

**

parts diagram and listModel MCS 300 page 6 of 16

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100 1051083 Connector Elbow 2101 1019253 Front Handle 1102 1010235 Dowel Pin 1103 1022211 Valve 2104 1054153 Threaded Plug 2105 1018020 Front Trigger Lever 1106 1024035 Trigger Guard 1107 1055134 Locking Screw 2108 1018171 Rear Trigger Lever 1109 1019255 Rear Handle 1110 1051321 Tubing Connector 1111 1051119 Tubing Connector 2112 1051313 “Y” Connector 1113 1061570 Tubing, Yellow 2 ft 2114 1061670 Tubing, Blue 2 ft 2115 1051124 Tubing Connector 2116 1050268 Elbow 2117 1012033 Trigger Guard Clamp 1118 1012056 Loop Clamp 1

3019304 Front Handle Assy (includesitems 7, 8, 100--107, 112--114and 117)

3019309 Rear Handle Assy (includesitems 71, 72, 96, 103, 104,108--110, 115 and 116)


Figure CDual TriggerHandles

parts diagramModel MCS 300page 7 of 16

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Figure DATD Control Box3063346 220V3063348 115V

parts list andspecial tools

Model MCS 300 page 8 of 16

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1 1055352 Socket Head Cap Screw 22 1004001 Washer 23 1051321 Tubing Connector 14 1071372 Plastic Tubing, 24 ft 15 1005059 Switch 26 1061670 Blue Tubing, 2 ft 17 1051091 Tubing Connector 28 1061255 Yellow Tubing, 20 ft 29 1051065 Pneumatic Actuator 210 1004154 Washer 211 1063862 Glass Fuse, 220v 1

1063612* Pigtail Fuse, 220v1072091 Glass Fuse, 115v 11063311* Pigtail Fuse, 115v

12 1051063 Tee 213 1051069 Air Bleed Fitting 214 1072072 ATD Circuit Board, 220v 1

1072071 ATD Circuit Board, 115v15 1029445 Hex Spacer 416 1004244 Internal Lock Washer 417 1073072 Plastic Screw 418 1034014 Air Filter 119 1051169 Connector Elbow 220 1061347 Black Tubing, 20 ft 121 1051316 Connector Elbow 122 1025049 Pressure Gage 1

ITEM PART NO. PART NAME QTY23 1022066 Pressure Regulator 124 1051059 Nipple 125 1055197 Socket Head Cap Screw 226 1004206 Washer 227 1007355 Lock Nut 228 1017012 Warning Label 129 1017391 Wiring Diagram Label, 220v 1

1017422 Wiring Diagram Label, 115v30 1016347 Electrical Enclosure 131 1032266 Mounting Plate, ATD Board 132 1063238 Hole Plug 133 1007278 Locking Nut 234 1004211 Sealing Ring 235 1063502 Wire Terminal Fork 1336 1011246 Cord Strain Relief Elbow 137 1011240 Cord Strain Relief 138 1001089 Electric Cord, 3 ft 139 1063079 Wire Terminal Ring 140 1055843 Fillister Head Screw 441 1072136 Din Connector, 220v 1

1072135 Din Connector, 115v42 1032681 Mounting Plate, Control 143 1050015 Reducer Bushing 144 1022332 Valve, Three Way, 115v 1

1022336 Valve, Three Way, 220v45 1051179 Air Exhaust Muffler 146 1050862 Tee, Air Inlet 1


* not used in current tools

Figure ESpecial Tools

THE FOLLOWING TOOLS ARE RECOMMENDED FORPROPER AND EFFECTIVE DISASSEMBLY AND AS-SEMBLY OF THE JARVIS MCS 300 AIR CIRCULARSAW.

NEEDLE BEARINGEXTRACTOR 8039168

BEARING CUP EXTRACTOR8039167

WRENCH 1061361

Parts for ATD Control Box

specifications, installationand operation instructions

Model MCS 300page 9 of 16

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SPECIFICATIONS

Motor Power 2 hp 1500 W

Operating Pressure 90 psi 6.2 bar

Air Consumption at 90 psi 67 ft3/min 1.9 m3/min

Blade Speed 1150 rpm

Control Handle Single or Dual Trigger Pneumatic

Blade Diameter 9.0 in 229 mm10.5 in 267 mm12 in 305 mm

Cutting Depth (max)9 inch blade 3 in 76 mm10.5 inch blade 3.4 in 86 mm12 inch blade 4.38 in 111 mm

Overall Length9 inch blade 22.7 in 577 mm10.5 inch blade 23.2 in 589 mm12 inch blade 24.2 in 615 mm

Weight 15.5 lbs 7.0 kg

Vibration less than (<) 125 dB < 1.78 m/sec2

Noise (one meter from tool) 91 dB

INSTALLATION INSTRUCTIONS

1 Suspend the MCS 300 from a balancer. Jarvis partnumber 4042040 is available.

2 Make the necessary air connection.

2.1 The required compressed air supply is 67ft3/min at 90 psi (1.9 m3/min at 6.2 bar).

2.2 Refer to Figure B on page 5 for single triggertools.

2.3 Refer to Figure C on page 6 for dual triggertools.

OPERATION INSTRUCTIONS

1 Each day, before you begin operation, go throughthe following checklist:

1.1 Make sure that the compressed air supply is atthe correct pressure and that the lubricator is upto the full mark. Use JarvisAirMist LubricatorOil; if using a conventional air mist lubricatorset the feed rate at 8--10 drops per minute; if us-ing a micro fog air mist lubricator set the feedrate at 100 drops per minute. Note: Almost allair mist lubricators are of the micro fog type.

1.2 Make sure that the saw moves freely on the ba-lancer.

1.3 Make sure that the saw is working correctly.

For Single Trigger Tools: Depress the triggerand the tool should start. Release the trigger andthe tool should stop. If the tool malfunctions, re-move it from service and report the problem toyour supervisor immediately.Always use two hands when starting and stop-ping the tool. Continue holding the saw firmlywith both hands until the blade comes to a com-plete stop.

For Dual Trigger Tools: Make sure the dualanti--tie down control handles are working cor-rectly. Depress each trigger separately and thetool should not start. Depress one trigger, thenpause one second and depress the other triggerand the tool should not start. Repeat this proce-dure reversing the triggers. Depress both trig-gers simultaneously (within one half second ofeach other) and the tool should start. With thetool running, release one trigger and the toolshould stop. Continue holding the depressedtrigger and then depress the other trigger. Thetool should not start. Repeat this procedureholding the other trigger. If the tool malfunc-tions, remove it from service and report theproblem to your supervisor immediately.Always use two hands when starting and stop-ping the tool. Continue holding the saw firmlywith both hands until the blade comes to a com-plete stop.

2 Making the cut:

2.1 Position the saw.

2.2 Depress the trigger(s) fully to start the saw andmake the cut. Alwaysuse twohandswhen start-ing the saw and while making the cut.

2.3 When the desired cut is reached, release the trig-ger(s). Continue holding the saw firmly withboth hands until the blade comes to a com-plete stop.

2.4 Withdraw the saw from the carcass.

maintenance instructionsModel MCS 300 page 10 of 16

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MAINTENANCE INSTRUCTIONS

IMPORTANT: ALWAYS DISCONNECT THE COM-PRESSED AIR SUPPLY IN ACCORDANCE WITHOSHA’S LOCKOUT/TAGOUT PROCEDURES (29 CFR1910.147) WHEN INSTALLING OR REMOVING THEBLADE. ALWAYS DISCONNECT THE AIR SUPPLY INACCORDANCE WITH OSHA’S LOCKOUT/TAGOUTPROCEDURES (29 CFR1920.147) BEFOREPERFORM-ING ANY MAINTENANCE OR REPAIRS.

Refer to Figures A--C on pages 4--6 for referenced items.

1 DAILY:

1.1 Add Jarvis 1315White Grease to the grease fit-tings (item 19) on the spur gear housing andplanetary housing (items 18 and 45).

1.2 Inspect all hoses for cuts and abrasions and re-place as necessary.

1.3 Check all fittings and connections for leaks andtighten or replace as necessary.

1.4 An air filter/regulator/lubricator (Jarvis partnumber 3022003) must be installed in the airsupply line. Keep the lubricator filled at alltimes.

1.5 Make sure that the saw is working correctly.Note: The air supplymust be connected to per-form this maintenance check only.

For single trigger tools: Depress the triggerand the tool should start. Release the trigger andthe tool should stop. If the tool malfunctions, re-pair or remove it from service immediately.Always use two hands when starting and stop-ping the tool. Continue holding the saw firmlywith both hands until the blade comes to a com-plete stop.

For Dual Trigger Tools: Make sure the dualanti--tie down control handles are working cor-rectly. Depress each trigger separately and thetool should not start. Depress one trigger, thenpause one second and depress the other triggerand the tool should not start. Repeat this proce-dure reversing the triggers. Depress both trig-

gers simultaneously (within one half second ofeach other) and the tool should start. With thetool running, release one trigger and the toolshould stop. Continue holding the depressedtrigger and then depress the other trigger. Thetool should not start. Repeat this procedureholding the other trigger. If the tool malfunc-tions, remove it from service and report theproblem to your supervisor immediately.Always use two hands when starting and stop-ping the tool. Continue holding the saw firmlywith both hands until the blade comes to a com-plete stop.

1.6 At the end of the shift/day, flush the air motor.

For Single Trigger Tools:

1.6.1 Remove quick connect socket (item 79)from the quick connect plug (item 78) lo-cated on the MCS 300.

1.6.2 Put about ten (10) drops of Jarvis Air MistLubricator Oil into the quick connect plug(item 78). Connect quick connect socket(item 79) and run the motor one minute.

For Dual Trigger Tools:

1.6.3 Remove tubing 1071372 from tubing con-nector (item 110).

1.6.4 Put about ten (10) drops of Jarvis Air MistLubricator Oil into the tubing connector(item 110). Insert tubing 1071372 into con-nector and run the motor one minute.

2 WEEKLY:

2.1 Remove the planetary gear head assembly(items 35--41) fromplanetary housing (item45).Refer to sections 8 and 9 as a procedural guide.

2.2 Apply Jarvis 1315 White Grease to the hole onthe end of planetary gear pins (item 41) to lubri-cate needle bearings (item 40).

Note: Planetary gear assembly (items 35--41)does not need to be disassembled to lubricateneedle bearings and planet gears. See Figure 1.

2.3 Apply a generous amount of Jarvis 1315 WhiteGrease to planet gears (item 39).

maintenance instructionsModel MCS 300page 11 of 16

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Figure 1Bearing and Gear Lubrication

PLANET GEAR

HOLE TOLUBRICATE

NEEDLE BEARING

DOWEL PIN

RETAININGRING

PLANETARYHUB

3 AS NECESSARY:

3.1 Clean and inspect circular blade. Refer to sec-tions 4 and 5 for blade removal and installationprocedures.

3.2 Disassemble, clean and inspect the spur gearhousing assembly, planetary housing assembly,air motor assembly, and handle and valve hous-ing assembly. Refer to sections 6 through 12 asa procedural guide.

4 CIRCULAR BLADE REMOVAL:4.1 Remove locking lever (item 1), depth gage

screw (item 2) and depth gage plate (item 3) ifapplicable.

4.2 Remove the blade nut (item 4). Jarvis wrench1061361 is available. See Figure E on page 8.

4.2.1 Place an awl or small screwdriver throughthe outer hole in blade to prevent it from ro-tating.

4.3 Remove the saw blade (item 5) and sharpen orreplace as necessary.

5 CIRCULAR BLADE INSTALLATION:5.1 Reverse procedures and steps outlined in section

4. See notes below. Refer to Figure 2 as a guide.5.1.1 To ensure proper fit and safe operation, the

hub of the saw blade (item 5) must face to-ward and fit securely on the extended lip ofthe spur gear.

5.1.2 Make sure notched areas on the saw bladeare aligned with ears on the spur gear.

LIP

BLADE

BLADENUT

SPURGEAR

EAR

OUTERHOLE

HUB ONOTHERSIDE

NOTCHEDAREA

Figure 2Blade Installation

BLADEROTATIONDIRECTION

5.1.3 When tightening blade nut (item 4), insertan awl or small screwdriver through the out-er hole in the blade to prevent blade fromturning. Jarvis wrench 1061361 is avail-able. See Figure E on page 8.

6 SPUR GEAR HOUSING DISASSEMBLY:6.1 Remove blade as described in section 4.6.2 Remove flat head screws (item 55).6.3 Remove blade guard assembly and auxiliary

handle assembly (items 6--9) as a complete unitfrom spur gear housing (item 18).

6.4 Remove dowel pins, o--ring and u--cup seal(items 10--12) from blade guard only if neces-sary.

6.5 Remove cheese head screws (item 77) and lockwashers (item 76). Remove spur gear housing(item 18) and planetary housing (item 45) as acomplete unit from motor housing (item 60).

6.5.1 Setmotor housing and rear handle assemblyaside.

6.6 Remove hex head screws (item 30) and lockwashers (item 29). Separate planetary housingassembly (items 24--45) as a complete unit fromspur gear housing (item 18).

6.7 Remove spur gear hex nut (item 20), left handthread.

6.7.1 Use a 5 mm allen wrench to hold spur gearpin (item 14) from moving while unscrew-ing spur gear hex nut (item 20), left handthread. Note: Use heat to loosen hex nut ifnecessary.


®JARVIS6201010:.




6.8 Remove entire spur gear assembly (items13--17) as one unit from spur gear housing (item18). Lightly tap front end of spur gear housing(item18)with nylonmallet to dislodge spur gearassembly if necessary.

6.9 Disassemble spur gear assembly (item 13--17).

6.9.1 Remove o--ring (item17) from spur gear pin(item 14).

6.9.2 Remove retaining ring (item 16), ball bear-ing (item 15) and spur gear pin (item 14)from spur gear (item 13).

6.9.3 Press ball bearing (item 15) from spur gearpin (item 14).

For Tools with Roller Bearings on Crown Gear:

6.10 Remove crown gear hex nut (item 21).

6.10.1 Use a 5mmallenwrench to hold crown gearpin (item 54) from moving while unscrew-ing crowngear hex nut (item21).Note: Useheat to loosen hex nut if necessary.

6.11 Remove o--ring (item 17) from back end of spurgear housing (item 18).

6.12 Remove entire crown gear assembly (items46--54) as one unit from spur gear housing (item18). Lightly tap front end of spur gear housingwith nylon mallet to dislodge spur gear assem-bly if necessary.

6.13 Disassembly crown gear assembly (item46--54). Be careful not to lose or damage shims.

6.13.1 Remove shims (item 46).

6.13.1.1 Label or mark shims between bearingcone (item 47) and spur gear housing(item 18) to aid in re--assembly if bothexisting crown gear (item 49) and spurgear (item 50) are not replaced. Makenote of the size and location of the shimsfor proper installation.

6.14 Remove crown gear pin (item 54).

6.15 Remove bearing cones (item 47) from bearingcups (item 48).

6.15.1 Remove bearing spacer (item 53) and shimsfrom between bearing cups (item 48).

6.15.1.1 Label or mark shims between bearingcones (item 47) to aid in re--assembly ifboth existing bearing cones and bearingcups are not replaced. Make note of thesize and location of the shims for properinstallation.

6.16 Remove bearing cups (item 48) from spur andcrown gear assembly. Jarvis special tool8039167 is available. See Figure E on page 8.Be careful not to score any parts.

6.17 Remove retaining ring (item 52) and press spurgear (item 50) and keys (item 51) from crowngear (item 49).

6.18 Clean and inspect all parts for wear and replaceas necessary.

For Tools with Ball Bearings on Crown Gear:

6.19 Remove crown gear hex nuts (item 23).

6.19.1 Use a 5mmallenwrench to hold crown gearpin (item 56) from moving while unscrew-ing crown gear hex nut. Note: Use heat toloosen hex nut if necessary.

6.20 Remove entire crown gear assembly (items 15,50--52, 56 and 57) as one unit from spur gearhousing (item 18). Lightly tap front end of spurgear housing with nylon mallet to dislodge spurgear assembly if necessary.

6.21 Disassembly crown gear assembly (items 15,50--52, 56 and 57).

6.21.1 Remove crown gear pin (item 56).

6.21.2 Remove retaining ring (item 52) and pressspur gear (item 50) and keys (item 51) fromcrown gear (item 57).

6.21.3 Remove ball bearing (item 15) from crowngear (item 57).

6.21.4 Remove flanged washer (item 22) andflanged spacer (item 58) from spur gearhousing (item 18).


7 SPUR GEAR HOUSING ASSEMBLY:

7.1 Reverse procedures and steps outlined in section6. See special notes below.


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For Tools with Roller Bearings on Crown Gear:

7.1.1 Make sure pinion gear and planetary hous-ing assembly (items 24--44) are installed be-fore making any backlash adjustments andprior to installing crown gear assembly(items 46--54).

7.1.2 Press one bearing cup (item 48) into gearside of crown gear (item 49). Press thebearing cup in fully.

7.1.3 Press the remaining bearing cup (item 48)into flat side of crown gear (item 49). Pressthe bearing cup in fully.

7.1.4 Make sure bevel end of retaining ring (item52) is facing away from spur gear (item 50)when installing onto crown gear (item 49).See Figure 3.

7.1.5 Make sure shims (item 46) and bearingspacer (item 53) are installed in exact loca-tion and according to size noted in steps6.13.1.1 and 6.15.1.1.

CROWNGEAR

NOTE BEVELDIRECTION

SPUR GEAR

RETAININGRING

Figure 3

7.1.6 If replacing tapered bearing cones and cups(items 47 and 48), proper clearance betweenthem must be set with bearing spacer (item53) and shims (item 46). Note: Shim pack-age (item 46) contains 5 shims 0.1 mm thickand 5 shims 0.2 mm thick. Install only asmany shims as necessary to achieve properclearance. Refer to Figure 4 as a guide forproper placement of shims and orientationof bearing cones and cups.

7.1.7 Remove all grease from bearings to proper-ly feel the clearance of the bearings.

7.1.8 Install the crown gear pin (item54), bearingcone (item 47), crown and spur gear assem-bly (items 49--52), bearing spacer (item 53),three thick shims (item 46) and other bear-ing cone (item47) into the spur gear housing(item 18).

7.1.9 Tighten crown gear pin (item 54). Checkthe clearance on the bearing cones (item47). The bearing cones should rotate freelywith no axial play. Decrease shim (item 46)thickness until all axial play is eliminated,while still allowing cones to rotate freely.

7.1.9.1 When assembled with crown gear hexnut (item 21) tight, there should be aslight resistance to the rotation of thespur gear assembly on the spur gear pin(item 14). A slight clearance betweenthe bearing cone and bearing cup is ac-ceptable as long as the crown gear as-sembly is stablewith no side to side playon the crown gear pin (item 54). Referto Figure 4 as a guide.

7.1.9.2 If bearing cones are tight, increase shimthickness until proper clearance isachieved.

7.1.9.3 If bearing cones are loose, decreaseshim thickness until proper clearance isachieved.

7.1.10 Remove the crown gear assembly (items47--54).

7.1.11 Re--install the crown gear assembly (items47--54) adding at least two shims (item 46)between the spur gear housing (item 18) andbearing cone (item 47). Make sure bearingcones and bearing cups are installed correct-ly.

7.1.12 Tighten crown gear pin (item 54).

7.1.13 Check the backlash between crown gear(item 49) and pinion gear (item 43). Rotatethe shaft of the pinion gear. The bevel gearsshould not have too much backlash nor betoo tight. The ideal backlash is0.004--0.005”. Increase the shim (item 46)thickness to increase the backlash; decreasethe shim thickness to reduce the backlash.See Figure 4.


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Figure 4Bearing Cone Clearanceand Backlash Adjustment

Place or Remove Shims Here to SetBearing Cone Clearance

SpacerBearing Cone Clearance Setting

Bearing Cone

Spur Gear Notes1. Set bearing cone clearance.

IF tight, add shims to achieve proper fit.IF loose, remove shims to achieve proper fit.

2. Backlash of crown gear should be 0.004” to 0.005”.3. Use Loctite 271 on threads of spur and crown gear pins.4. Pack all bearing cones and cups with Jarvis 1315 WhiteGrease when clearance adjustments are completed.

Spur GearHousing

Bearing Cup

Place Shims Here to Set BearingCrown Gear Backlash

PlanetaryHousing

CrownGear

7.1.14 After determining the correct amount ofshims (item 46), remove the crown gear as-sembly and shims (items 46--54).

7.1.15 Pack bearing cones and bearing cups withJarvis 1315 White Grease.

7.1.16 Reinstall crown gear assembly and shims.Apply Loctite 271 to threads of crown gearpin (item 54).

For all Tools:

7.1.17 Fill the cavity of spur gear housing (item18)with Jarvis 1315 White Grease.

7.1.18 Make sure beveled end of retaining ring(item 16) is facing toward spur gear housing(item 18) when installing into spur gear(item 13). See Figure 5.

7.1.19 Apply Loctite 271 on threads of spur gearpin (item 14).

7.1.20 Make sure o--rings (items 11 and 17) areseated and installed properly in grooves ofspur gear housing (item 18) and spur gearpin (item 14). Apply a light coat of Jarvis1315 White Grease to o--rings to keep themin place when assembling, if necessary.

SPUR GEARNOTE BEVELDIRECTION

RETAININGRING

Figure 5

SPUR GEAR PIN

GEAR HOUSING

BALL BEARING

8 PLANETARY HOUSING DISASSEMBLY:8.1 Separate planetary housing assembly (items

24--44) as a complete unit from spur gear hous-ing (item 18). Follow steps and procedures out-lined in section 6, steps 6.1--6.6.

8.2 Remove flat head screw (item 37) and piniongear washer (item 36).

8.3 Remove planetary gear assembly (items 35 and38--41) from pinion gear (item 43). Lightly tapmotor housing end of planetary housing (item45) with nylonmallet to dislodge planetary gearassembly if necessary.


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8.4 Remove retaining rings (item 38).

8.5 Remove planetary gear pins (item 41), planetgears (item 39) and needle bearings (item 40)from planetary gear hub (item 35). Use a drivepunch if necessary.

8.6 Remove planetary gear pins (item 41) andneedle bearings (item 40) from planet gears(item 39). Jarvis special tool 8039168 is avail-able. See Figure E on page 8. Be careful not toscore any parts.

8.7 Remove retaining ring (item 34).

8.8 Remove pinion gear (item 43), ball bearing(item 33), inner race (item 42) and key (item 32)from planetary housing (item 45). Lightly tapgear housing end of planetary housing with ny-lon mallet to dislodge pinion gear assembly.Use and arbor press if necessary.

8.9 Remove key (item 32).

8.10 Press ball bearing (item 33) and inner race (item42) from pinion gear (item 43).

8.11 Remove o--ring (item 24).

8.12 Press needle bearing (item 28) from planetaryhousing (item 45).


9 PLANETARY HOUSING ASSEMBLY:

9.1 Reverse procedures and steps outlined in section8. See notes below.

9.1.1 Make sure o--ring (item24) is seated proper-ly in planetary housing.

9.1.2 Make sure bevel end of retaining ring (item34) is facing toward air motor housingwhen installed into planetary housing (item45). See Figure 6.

AIR MOTORHOUSING

ROTOR

NOTE BEVELDIRECTION

RETAINING RING

Figure 6

GEAR HOUSING

BALL BEARING

10 MOTOR HOUSING DISASSEMBLY:

10.1 Remove cheese head screws (item 77) and lockwashers (item 76).

10.2 Separate the motor housing assembly and rearhandle assembly as a complete unit from plane-tary housing assembly.

10.3 Separate the motor housing assembly from rearhandle assembly.

10.4 Slide motor housing assembly (items 62--69, 98and 99) frommotor housing (item 60). For easeof removal and installation, use a heat gun to ap-ply heat to motor housing, if necessary.

10.5 Remove rotor screw (item 69). Use 12 mmwrench on flats on rotor to prevent rotor fromturning.

10.6 Lift off rear motor plate (item 98) and ball bear-ing (item 62) from air motor sleeve (item 68).Use a drive punch if necessary. See note below.

10.6.1 Place drive punch in hole of rotor shaft andlightly tap until rear motor plate and ballbearing is free from rotor shaft.

10.7 Slide rotor and bearing assembly (items 62--67)from air motor sleeve (item 68).

10.8 Remove dowel pins (item 99) if necessary.

10.9 Remove vanes (item 66).

10.10 Press ball bearing (item 62) from splined end ofrotor (item 65). Remove wave spring (item 63).

10.11 Remove o--ring (item 59) from motor housing(item 60).



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AIR MOTORHOUSING

ROTOR

Figure 7 REAR HANDLEASSEMBLY

CHEESE HEADSCREWS

Notes1. Tightened cheese head screws evenly in a crisscross pattern.2. Make sure rotor rotates freely as you tightened screws.

1

2

3

4

CRISSCROSSPATTERN

11 MOTOR HOUSING ASSEMBLY:


11.1.1 Make sure o--ring (items 59) is seated prop-erly in motor housing.

11.1.2 Install motor housing assembly (items62--69, 98 and 99) as a complete unit intomotor housing. For ease of removal andinstallation, use a heat gun to apply heat tomotor housing, if necessary.

11.1.3 When installing rear handle assembly,tighten cheese head screws (item 77) evenlyusing a crisscross pattern. Make sure rotor(item 65) rotates freely as you tightencheese head screws. Refer to Figure 7 as aguide.

12 HANDLE AND VALVE HOUSING DISASSEM-BLY:

12.1 Remove cheese head screws (item 77) and lockwashers (item 76).

12.2 Separate the motor housing assembly and rearhandle assembly as a complete unit from inter-mediate housing assembly.

12.3 Separate the motor housing assembly from rearhandle assembly.

12.4 Remove threaded pin (item 96) from handle andvalve housing (item 74 or 109).

12.5 Remove trigger (item 73 or 108) from handleand valve housing (item 74 or 109).

12.6 Press bushing (item 72) and dowel pin (item 71)from trigger (item 73 or 108) if necessary.

For Single Trigger Tools:

12.7 Remove valve plug (item 85), o--ring (item 86)and compression spring (item 87) from handleand valve assembly.

12.8 Slide valve plunger assembly (items 88--93)from handle and valve housing as a completeunit.

12.9 Unscrew valve screw and spring guide (item 88)from valve plunger (item 93) and separateplunger assembly.

12.10 Remove external retaining ring (item 92) andvalve seal (item 91) from seal housing (item90).

12.11 Remove o--ring (item 89) from valve screw andspring guide (item 88).

For Dual Trigger Tools:

12.12 Remove threaded plug (item 104) and valve(item 103) from rear handle and valve assembly.

12.13 Remove locking screws (item 107) and triggerguard (item 106) from front handle (item 101).

12.14 Remove dowel pin (item 102) and front triggerlever (item 105).

12.15 Remove threaded plug (item 104) and valve(item 103) from front handle and valve assem-bly.

For All Tools:

12.16 Remove o--rings (items 70 and 97).


13 HANDLE AND VALVE HOUSING ASSEMBLY:


13.1.1 Make sure o--rings (items 59, 70, 86 and 97)are seated properly.

13.1.2 Make sure valve plunger (item 93) slidesfreely through bushings (item 94). Note:Bushings are press fitted into handle andvalve housing and usually do not need to beremoved.

13.1.3 When installing rear handle assembly,tighten cheese head screws (item 77) evenlyusing a crisscross pattern. Make sure rotor(item 65) rotates freely as you tightencheese head screws. Refer to Figure 7 as aguide.

Documents

JARVIS · noticetoemployer and safety director Model MCS 300 page 2 of 16 JARVIS® 6201010:. PRODUCTS CORPORATION 33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457--4926 UNITED STATES