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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
Warning
before proceeding.
-
NOTE
NOTE
Valves
NOTE:
The following metric wrenches are needed:
M10, M13 and
M30.
Repair kits are available.
Refer
to
the individual repair sections and the
pump parts page for more details. For the best
results, use all parts in the kits.
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.
For a set of six valves, order P/N 801-472.
1. Remove the hex plug from the manifold using an
M30 wrench.
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 newvalve. Install the O-ring and hex plug;
torque
to
75
It-lb
(103 Nm).
NOTE:
Retorque the plug after
5
hours of operation.
Pumping Section
1. Remove the eight capscrews and lockwashers from
the manifold using an M13 wrench.
2.
Carefully separate the manifold from the crankcase.
NOTE
It
may be necessary
to
tap the manifold lightly
with a
soft
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
Plunaer reDair kit. P/N 801-474 is available
to
1,
2.
3.
4.
5.
6.
I.
..
backup rings for three cylinders.
replace retainers, O-rings, washers and
Loosen the plunger retaining screw five
to
six turns,
using an MlOwrench. Push the plungertowards the
crankcase to separate the plunger and retaining
screw.
the O-ring, backup ring and copper bearinggasket
Remove the screw from the plunger and examine
washer. Replace these parts,
if
necessary, using kit
801-474.
Remove the plunger and flinger from the plunger
shaft. Clean, examine and replace parts as
necessary.
crankcase. If leaking is
obvious, replace the
oil
Inspect the
plunger shaft
for oil leakage from the
seals. Otherwise,
DO
NOT
remove these seals as
they cannot be reused.
An
oil seal kit
is
available to
replace the seals.
Lightly grease the flinger and oil seal,
if
it is being
replaced and replace them on the plunger shaft.
Then install the plunger.
of the plunger. Place the washer, O-ring and backup
Lightly grease the retaining screw and the outer end
the plunger. Torque
to
14.4 ft-lb (19.5 Nm).
ring around the screw and install the screw through
NOTE
If
you plan
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.
Torquethe screws
to
21.7 ft-lb
(29
Nm)
following the
tightening pattern (Figure 4). Uneven tightening
may cause the manifold
to
bind or jam.
I
I
Flgure
4
18
308-528