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PUMP
SERVICE
To
reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, or
~A~~O~~
injury from moving parts, always follow the Pressure Relief Procedure Warning on page 7 before
proceeding.
NOTE:
The following metric wrenches are needed: M6 Allen wrench, M10, and M30.
A pump repair tool kit, P/N 800-271,
is
available. It includes packing, extraction and insertion tools
Repair kits are available. Refer to the individual repairsections, and the parts pagefor more details. For
the best results, use
all
the parts in the kit.
Valves
NOTE:
To replace valves, order kit part no. 801
-
472.
1. Remove the hex plug (205) from the manifold
(206) using an M30 wrench..
2.
Examine the O-ring (204) under the plug and
replace
it
if it is cut or distorted.
3.
Remove the valve assembly(203)from thecavity;
the assembly may come apart.
4.
Install
a
new valve (203). Install the O-ring (204)
and plug (205) and torque'to 75 ft-lb (10.3 Nm).
NOTE:
Retorque the plug after 5 hours of
..
operation.
Pumping Section
1. Remove the eight Allen head cap screws (201)
and lockwasher (202) from the manifold (206)
using
a
M6 Allen wrench.
2. Carefully separate the manifold from the
crankcase. It may be necessry to tapthe manifold
lightly with
a
rubber mallet.
CAUTION
To
avoid damaging
the
plungers or seals, keep
plungers when removing
it.
the manifold properly aligned with the ceramic
-
3.
Carefully examine each plunger (221) and
replace
it
if there is any scoring.
Servicing
The
V-Packings
NOTE: To replace just the v-packings, use kit
part
no.
801 -662 which
will
service the
entire pump.
-To replace the v-packings, rings and
retainers, orderthree ofkit part no. 801
-
,.,
..
,
.
.
:
. ..
664 to service the entire pump.
;:
:
,_
..
1. If the manifold is not already removed, follow
Steps 1 and 2
of
pumping section.
2.
Carefullypull the packing retainer(214)from the
manifold. Examine the O-ring (21 5) and replace it
if it
is
cut or damaged.
3. Remove the v-packing (212)and head ring (21 1).
Pull
out the intermediate retainer ring (213).
Remove the v-packing (21 2) and head ring (21 1).
4.
Inspect
all
parts and replace as necessary.
5.Thoroughly clean the packing cavities and
examine.
6. Lightly grease. the packing cavities and then
replace the packings in the following order: head
ring (211). v-packing (212). intermediate ring
(213),headring(211),packing(212),andpacking
the retainer groove.
retainer(214). with the O-ring (215) installed into
order and facing the correct direction. See
Figure
4.
Improperly installed parts will cause
a
malfunction.
7.
Reassemble the manifold as instructed in Steps 7
and
8
of Servicing The Plungers.
Servicing
The
Plungers
NOTE:
Plunger repair kit, part no. 801-474,
is
available to service all the plungers.
1.
Loosen the plunger retaining screws (21 7).
5
to 6
turns, using an M10 wrench. Push the plunger
(221) toward the crankcase to separate the
plunger and retaining screw.
2. Remove the screw (217) from the plunger and
examine the
O-ring
(21
9).
backup ring (220) and
copper bearing/gasket washer (218). Replace
these parts, if necessary, using kit part no.
801
-
474.
3.
Remove the plunger (221) and flinger (222)from
the plunger shaft. Clean, examine and replace
parts as necessary.
802-777
9