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16 D04-991-2400 5/1/04
D/G-04 Service (Hydraulic End)
3. Replace Shaft Seal
NOTE: Inspect the shaft seal (54) before continuing. If
it looks damaged in any way, replace it.
a. Press the back bearing (55) and seal (54) out of the cover
(52). Discard the seal.
b. Apply a coating of Loctite High-Performance Pipe Sealant
with Teflon
©
, or a comparable product, to the outer
surface of a new seal and the inside surface of the
opening in the back cover (52) where the seal will rest.
c. Press the new seal into the back cover.
d. Inspect the bearing (55). If pitted or damaged, replace
it.
e. Apply a coating of Loctite Rc/609 Retaining Compound
or comparable product to the outer surface of the bearing.
Press the bearing into the back cover until it rests on the
shoulder. The shield on the bearing must face away from
the back cover.
4. Reassemble Housing and
Back Cover
a. Stand the pump on end.
b. With the pistons and connecting rods in place, reinstall
the crankshaft by threading it through the connecting
rods.
c. Reinstall the back cover, cover O-ring, and bolts (with
their O-rings).
5. Reinstall Diaphragms
a. Screw the plunger guide lifter (from the Wanner Tool Kit
or Repair Kit) into the valve plunger (24). Pull out to
expose the cross holes in the plunger. Rotate the shaft
until the piston is at top dead center.
b. Insert the plunger holder tool (from the Wanner Tool Kit),
through the plunger hole — to hold the plunger away
from the diaphragm plate (18), and to keep the plunger
from turning when the diaphragm is being installed.
c. Engage the diaphragm insert threads to the plunger
threads, and turn the diaphragm by hand until the insert
hits the shoulder of the valve plunger (24).
d. Hold the plunger holder tool to secure the valve plunger,
and torque the diaphragm insert to 10 in.-lbs (110 N-cm)
using a 5/16-in. (8-mm) open-end wrench.
e. Repeat the above procedure for the plungers and
diaphragms of the other two cylinders.
f. Fill the reservoir with fresh oil and prime the pump, as
outlined in the Fluid-End Service Section.
6. Reassemble Pump
Reassemble the pump as outlined in the Fluid-End Service
Section.