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PUMP
SERVICE
WARNING
To
reduce the risk of serious bodily injury,
including fluid injection, splashing in the eyes or
on the skin, or injury from moving parts, always
follow the Pressure Relief Procedure Warnlng
before proceeding.
1
NOTE:
The following metric wrenches are needed:
Refer
to
the individual repair sections and the
M10, Mi3 and M30. Repair kits are available.
pump parts page formore details. For the best
results, use all parts in the kits.
NOTE
There are
two
different
tool
kits
to
aid
in
servicing the pump. P/N 800-298 is used
to
ease installation of packings. P/N 800-271
includes the items
in
800-298
and
tools
to aid
in the removal of packing retainers.
Valves
NOTE:
For a
set
of six valves, order
P/N
801
-472.
1.
Remove the hex plug from the manifold using an
M30 wench.
2. Examine the O-ring under the hex
plug
and replace
it
if
it
is cut or distorted.
3. Remove the valve assembly from the cavity; the
assembly may come apart.
4.
Install the new valve. instail the O-ring and hex plug;
torque
to
75
fl-lb
(103
Nm).
NOTE
Retorque the plug afler
5
hours of operation.
Pumping Section
1.
Remove the eight capscrews and lockwashers from
the manifold using an Mi3 wrench.
2.
Carefully separate the manifold from the crankcase.
NOTE:
it may be necessaryto tap the manifold lightly
with a sofl mallet
to
loosen.
CAUTION
Keep the manifold properly aligned with the
ceramic plungers when removing
to
avoid
damage
to
the plunger or seals.
3. Carefully examine each plunger for any scoring or
cracking and replace as necessary.
Servicing
the
Plungers
NOTE
Plunger repair kit, P/N 801-474 is available
to
replace retainers, O-rings, washers and
backup rings for three cylinders.
1. Loosen the plunger retaining screw five
to
six tums,
using an MI0 wrench. Push the plunger towards
the
crankcase
to
separate the plunger and retaining
screw.
2.
Remove the screw from the plunger and examine
the O-ring, backup ring and copper bearindgasket
washer. Replace these parts, if necessary, using kit
801
-474.
3.
Remove the plunger and flinger from the plunger
shafl. Clean, examine and replace parts as
necessary.
4.
Inspect the plunger shaft for oil leakage from the
crankcase. if leaking is obvious, replace the oil
they cannot be reused.
An
oil seal kit is available
to
seals. Otherwise,
DO
NOT remove these seals as.
replace the seals.
5.
Lightly grease the flinger and oil seal,
if
it is being
Then install the plunger.
replaced and replace them on the plunger snafl.
6.
Lightly grease the retaining screw and the outer end
of the plunger. Place the washer, O-ring and backup
the plunger. Torque
to
14.4 fl-lb (19.5 Nrn).
ring around
the
screw
and
instail
the
screw through
NOTE:
if you pian
to
replace the packings, refer
to
Servicing the V-Packings.
7.
Lubricate the outside of each plunger. Slide the
manifold onto the crankcase, being careful not
to
damage the seals.
8.
Install
the
capscrews and washers finger-tight.
Torque the screws
to
21.7 fl-lb
(29
Nm) following the
tightening pattern (Figure
4).
Uneven tightening
may cause the manifold
to
bind
or jam.
I
1
3
2
6
I
Figure
4
16
308-535