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PUMP SERVICE
To reduce the risk of serious bodily injury, including fluid injection, splashing
injury from moving parts, always follow the Pressure Relief Procedure Warning on page 7 before
proceeding.
NOTE:
The following metric wrenches are needed: M 6 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
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
if it is cut or distorted.
it
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.
. .
P u m p i n g S e c t i o n
1. Remove the eight Allen head cap screws (201)
and lockwasher (202) from the manifold (206)
using a M 6 Allen wrench.
2. Carefully separate the manifold
crankcase. It may be necessry to tapthe manifold
lightly with a rubber mallet.
To
avoid damaging
the manifold properly aligned with the ceramic
plungers when removing it.
3.
Carefully examine each plunger (221) and
replace
if there is any scoring.
it
The
Servicing
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
.
..
664 to service the entire pump.
,
.
. . .
:
,
.
,
:
;
:
,_ ..
1. If the manifold is not already removed, follow
Steps 1 and 2 of pumping section.
all
the parts in the kit.
from the
CAUTION
the
plungers or seals, keep
V-Packings
~
A
2.
-
Carefullypull the packing retainer(214)from
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
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
retainer(214). with the O-ring (215) installed into
the retainer groove.
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
8
and
of Servicing The Plungers.
Servicing The Plungers
-
NOTE:
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
copper bearing/gasket washer (218). Replace
these parts, if necessary, using kit part no.
-
no. 801
474.
3.
Remove the plunger (221) and flinger (222)from
the plunger shaft. Clean, examine and replace
parts as necessary.
~
~
O
in the eyes or on the skin, or
Plunger repair kit, part no. 801-474, is
available to service all the plungers.
9).
backup ring (220) and
~
~
the
and
-
801
9
802-777
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