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NOTE:
Three sizes of metric wrenches are
M10
and M6 Allen wrench.
necessary for servicing the pump;
M30,
Valves:
1.
Remove the hex plug (5)from manifold
(6)
using
M30
wrench.
2. Examine O-ring
(4)
under plug and replace if cuts or
distortion exist.
3.
Remove valve unit and O-ring
(3)
from cavity.
NOTE:
Valve
unit
may comeapartduring removal.
4.
Replace valve unit with P/N 801 -472.
5. Replace hex plug and torque to75ft. Ibs.
(10.3
K/m).
NOTE:
Hex plug should be re-torqued after 5
hours operation.
Pumping
Section:
1. Remove the eight Allen head cap screws (1) from
the manifold using the
M6
Allen wrench.
2. Carefully separate the manifold from the crankcase.
NOTE:
It
may be necessary to tap manifold lightly
r
1
with mallet to loosen.
plungers when removing to avoid damage to
Keep manifold properly aligned
with
ceramic
plungers or seals.
3.
Carefully examine each plunger (21) for any
scoring and replace if necessary.
Servicing Plungers:
1.
Loosen plunger retaining screw (17) 5-6 turns,
crankcase. This
will
separate plunger and
using "10 wrench. Push plunger towards
retaining screw.
2. Remove retaining screw from plunger and
examine O-ring (1
9).
back-up ring (ZO), and copper
bearing/gasket washer (18). Replace if necessary
using plunger repair kit P/N 801-663.
3;
Remove plunger from plunger rod and remove
copper flinger (22). Clean or replace
if
necessary.
4. Lightly grease flinger and replace
it
on
plunger
rod.
5. Replace plunger.
6. Lightly grease retaining screw assembly to avoid
cutting O-ring. Lightly grease outer end of plunger.
7. Install retaining screw assembly into plunger and
torque
to
14.4 ft. Ibs. (2 K/m).
8.
Lubricate each plunger and carefully slide manifold
onto crankcase.
9.
Replace the eight capscrews and snug them up.
Torque
to
16
ft.
Ibs.
(2.2 K/m).
NOTE:
The eight capscrews must be torqued
evenly to apply equal pressure on the
manifold
so
that
it
seats properly and
doesn't bind or jam. This is best done by
torquing bolts closest
to
the center of the
manifold first and then working out from
those bolts.
Servicing V-Packings:
NOTE:
Use packing repair kit PIN 801-662.
1.
After removing the eight capscrews and the
manifold carefully pull packing retainer (14) from
the manifold. Examine O-ring (15) and replace
if
necessary.
(11).
2.
Remove low pressure packing (12) and head ring
3. Pull intermediate retainer ring(l3)from manifold,
high pressure packing (12) and head ring (1 1
).
4.
Inspect all parts and replace if necessary.
NOTE:
If just the packings are'needed use kit
801-662. If rings or retainers need
replacement
use
kit 801
-664.
5. Thoroughly clean packing cavity
in
manifold and
6.
Replace packing assembly
in
the following order:
headring(ll),packing(12),intermediatering(l3),
head ring
(1
1). packing (12), packing retainer(l41
and O-ring (15).
examine. Lightly grease packing cavity.
Carefully study the location of each part and the
CAUTION
position of the seals
to
assure proper reassembly
and operation.
7.
Lubricate each plunger and carefully slide manifold
onto
crankcase.
NOTE:
When replacing .the manifold onto
plungers, extreme caution should be
exercised
to
avoid damage
to
the seals.
8.
Replace the eight capscrews
in
the manifold and
tighten as previously described (step
9
under
servicing plungers).
8
801-641
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