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Water Pump Head Service (Fig. 36)
The three major wear components in the high pressure
pump that require maintenance include: the check val-
ves, plunger sleeves, and plunger seals. These com-
ponents will require maintenance after approx. 500
pump operating hours (approx 750 engine hours).
j
High pressure water system components can
cause personal in ury if disassembled incor-
rectly. Discharge water pressure at bleed
valve before attempting any water system
servicing. Open bleed valve slowly and avoid
contact with high velocity water stream.
WARNING
NOTE: Because of high torque requirements for check
valve caps and difficulty of correctly installing check
valves in horizontal position, it is recommended that the
pump head be removed from the crankcase when ser-
vicing.
NOTE: Whenever a pump is removed from the machine
for preventative maintenance or servicing, replace com-
ponents in complete groups rather than individually.
Complete servicing will increase the service interval
between repairs.
Pump Head Removal
1. Remove pump from machine (see Water Pump
Removal and Installation).
2. Remove eight (8) nuts (Item 17). Carefully move
pump head (Item 11) away from pump crankcase. Turn
pump crankcase to help in removal of pump head.
Check Valve Replacement (replace as a set)
1. Remove the six caps (Item 7) and pull out check valve
assemblies.
2. Discard old check valves (Item 9) and remove any
remaining seals (Item 10) stuck in the pump head.
3. Insert new seals (Item 10) and check valves (Item 9).
4. Install new seals (Item 8) in check valve caps. Apply
Loctite 242 or equivalent to threads, install caps and
tighten to a torque of 205 - 235 ft-lbs.
1
2
3
4
5
6
PLUNGER SEAL REMOVAL - Step 2:
Fill the three (3) plunger openings with water.
Insert Pump Seal Extraction Tool (TOR4013) into
each water filled cavity. Quickly, strike the
extraction tool with a heavy lead mallet. Seal
assembly and brass retainer should move about
1/4 in. out of the cylinder head. If seal does not
move, add more water and try again. If the seal
does not move after a few attempts, try using
heavy oil or grease instead of water.
PLUNGER SEAL REMOVAL - Step 1:
Fill outlet port of pump head with water and
7
use two capscrews, to temporarily install
Pump Seal Outlet Cover (TOR4014) onto
the outlet port of the pump head.
8
9
10
11
12
13
18
17
16
8
9
10
15
14
Use Loctite 242 or equivalent
Torque to 205 - 235 ft-lb.
Torque to 25 - 33 ft-lb.
(Eight locations)
7
(Six locations)
Figure 36
Repairs Page 6 - 24 HydroJect
™
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