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Removing the Piston Rod Assembly
Refer to the parts listing for the fluid section assembly.
1. Position the inlet valve housing (26) in a vise so that the
fluid section is vertical. Tighten the vise.
2. Position a large adjustable wrench on the wrench flats of
the cylinder (8). Turn the cylinder counterclockwise until
the cylinder is removed from the inlet valve housing.
3. Remove the inlet valve housing from the vise. Tap out the
inlet ball cage (22) and ball stop pin (21).
4. Remove the inlet valve carbide seat (24). Inspect the inlet
valve ball and the inlet ball seat for damage. If the seat is
worn or damaged, it can be flipped to the unused side. If
you flip or replace the seat, the ball must be replaced.
5. Remove the inlet valve seat O-ring (25) from the inlet
valve housing.
6. Position the wrench flats of the cylinder (8) in a vise and
tighten the vise.
Do not over tighten or you might damage the cylinder.
7. Remove the packing nut (1).
Hold a hand under the piston rod (16). The piston rod
may be damaged if it falls. The lower packings may also
fall out.
8. Gently tap down the piston assembly with a rubber mallet
until the piston assembly comes out.
Cleaning the Piston Rod
1. Remove the cylinder from the vise.
2. Position the piston rod assembly in the vise and tighten.
The piston rod may be damaged if you are using a vise
with steel jaws. Use a vise with aluminum jaws or take
precautions to protect the piston rod.
3. Remove the retaining nut (20).
4. Remove the outlet valve seat (19), the outlet ball (18), the seal
washer (27) and the outlet ball cage (17). Inspect the outlet
valve ball and the outlet valve ball seat for damage. If the
seat is worn or damaged, it can be flipped to the unused side.
If you flip or replace the seat, the ball must be replaced.
5. Remove the lower packings (12, 13), the pressure ring (11),
the wave washer (10), and the O-ring (9) from the cylinder (8).
6. Soak the new leather packings in linseed oil for 5 minutes.
Do not over-soak.
7. Clean the disassembled parts in an appropriate solvent.
8. Install the outlet ball cage (17), the outlet ball (18), the
seal washer (27), and the outlet valve seat (19) in that
order into the piston rod.
9. Apply removable threadlocking compound to the retaining
nut threads (20) and screw the retaining nut into the
piston rod. Torque the retaining nut to 24 ft./lbs. Remove
the piston assembly from the vise.
CAUTION
CAUTION
CAUTION
NOTE: If the carbide valve seat requires
replacement, use valve kit P/N 0294979.
NOTE: If any parts are difficult to disassemble, soak
them in an appropriate solvent until the paint
softens.
Replacing the Packings
1. Position the wrench flats of the cylinder (8) into the vise
and tighten the vise.
2. Insert the wave spring (6), pressure ring (5), upper
packings (3, 4) and adapter (2) into the cylinder (8).
3. Loosely thread the packing nut (1) into the cylinder.
4. Remove the cylinder from the vise, rotate it, and replace it
in the vise so that the bottom of the cylinder is facing up.
5. Insert the wave spring (10), the lower pressure ring (11),
the lower packings (12, 13), the lower ring support (14),
and the O-ring (15) into the cylinder.
Inserting the Piston Rod
1. Insert the piston rod assembly into the cylinder.
2. Insert the O-ring (25) into the inlet valve housing (26).
3. Insert the inlet ball seat (24) and the inlet ball (23) into the
inlet valve housing.
4. Insert the stop pin (21) into the inlet ball cage (22) and
place them into the inlet valve housing (26).
5. Place the O-ring (9) into the inlet valve housing.
6. Thread the inlet valve housing assembly onto the bottom
of the cylinder assembly. Torque to 75 ft./lbs.
7. Install the large locknut (7) onto the cylinder and turn it until
the nut bottoms out on the threaded section of the cylinder.
Attaching the Fluid Section
1. Remove the assembled fluid section from the vise. Apply
anti-seize compound on the upper cylinder threads and
thread it into the pump housing. The piston rod (16) will
align itself with the slide block.
2. Rotate the fluid section so that the hole in the slide block
is aligned with the hole in the piston assembly.
3. Slide the connecting pin through the holes in the slide
block and the piston assembly.
4. Replace the cotter pin to hold the connecting pin securely.
Refer to the illustration on the previous page.
5. Screw the fluid section into the pump housing as far as it
will go. Then unscrew it slightly so that the outlet elbow
will align with the fluid hose.
6. Firmly tighten the locknut (7) by turning it clockwise until it
is secured tightly against the drive housing. Torque to 150
ft./lbs.
Replacing the Motor Brushes
Brushes should be inspected periodically for wear. If one of
the brushes measures less than 1/2", is worn or is chipped,
then replace both of the motor brushes. It is recommended
that the brushes be replaced when the packings are replaced.
ALWAYS follow the PRESSURE RELIEF PROCEDURE
found in your manual before starting any troubleshooting,
servicing or cleaning.
WARNING
NOTE: Make certain to alternate the UHMWPE and
leather packings as shown in the illustration.
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