Filter
Top Products
Hydroject 3000
Page 6 – 26.1
Repairs
Rev. B
Water Pump Crankcase Service (Model 09801) (Fig. 38b)
12
3
4
56 7 8
9
22
15
18
19
20
21
23
24
25
26
27
28
29
10
11
12
13
14
7
8
14
13
22
10
17
16
10
Apply grease to
O.D. of plunger
before installing
pump head
18 – 20 ft–lb
18 – 20 ft–lb
18 – 20 ft–lb
Figure 38b
NOTE: Replace parts in complete sets.
1. Remove water pump from machine (see Water Pump
Removal and Installation).
2. Remove pump head (see Pump Head Service).
3. Remove pulley from pump drive shaft using 1/4 in.
bolts to separate tapered hub.
4. Remove rear cover (Item 20).
5. Remove connecting rod end caps (Item 13) and keep
them in original order. Carefully push connecting rods
(Item 12) forward.
6. Remove crank rod bearing caps (Item 9, 27), keeping
shims (Item 8) in their original locations. Slide crank rod
(Item 15) out of the crankcase. Inspect crank rod for gall-
ing or wear.
7. Pull connecting rods (Item 12) out through crankcase.
Check for wear on plunger (12) and plunger guides
(Item 28). If plunger guides are worn, use Wear Sleeve
Tool (TOR4015) to drive guides out through crankcase.
Also use this tool for plunger guide installation.
8. Inspect bearings (Item 23) for galling and pitting. If
bearings are worn, replace bearings and bearing cups
as a set.
9. Install new seal (Item 11) and O–rings (Item 7) and
install crank rod, bearings and caps into crankcase.
10. Bearings should have a light pre–load, eliminating
any end play. Add or remove end cap shims (Item 8) to
change pre–load (see Crankshaft Bearing Installation
and Shimming Page 6–26.2).
Preload: 0.005 – 0.007
Capscrew torque: 18–20 ft–lbs
11. Install end caps onto connecting rods and torque
capscrews (Item 10) to 18 ft–lbs.
12. Install new gasket, crankcase cover, and torque
crankcase cover capscrews (Item 10) to 18 ft–lb.
13. Install pulley with tapered hub onto pump drive shaft.