19
6)
If the crankcase oil seals (19) are to be replaced, they can be removed by prying loose. Take care
not to make contact with the plunger. If the oil seals are not to be replaced, proceed to the back
end disassembly sequence and carefully pry the seals loose after the plungers have been removed
from the crankcase.
DISASSEMBLY SEQUENCE OF THE
CRANKCASE
1)
Before beginning, drain the oil from the crankcase, through the oil drain (3A).
2)
Remove the crankcase cover (3) and O-ring (4) from the crankcase (1). To remove the crankshaft
(13), remove the bearing cover (7) and sight glass (8). Using a rubber mallet, remove the crankshaft
axially through the connecting rods by tapping on the end of the shaft. Do not bend or damage the
connecting rods during crankshaft removal.
3)
Next remove the remaining bearing and radial shaft seal (11). Inspect both bearings and seal for
wear and replace if necessary.
4)
Remove the connecting rod (15), then the plunger (16) and wrist pin (17), if necessary. Check the
plunger bore in the crankcase for wear. Inspect parts and replace as necessary.
5)
Should you find it necessary to service the plunger assembly (16), you can do so by removing the
tension screw (16D). Inspect all parts and replace as necessary.
Note:
In order to drive the pump from the side opposite the present shaft extension, simply
remove the valve casing from the crankcase and rotate the pump 180 degrees to the desired
position. Be certain to rotate the seal case as well, so that the weep holes are down at the six
o’clock
position. Change the oil fill and the oil drain plugs. Refer to the repair instructions
as necessary for the proper assembly sequence.
REASSEMBLY SEQUENCE
1)
Reassemble plunger (16) and the connecting rod (15) with wrist pin (17). Place assemblies in
crankcase (1). Install crankshaft through connecting rods, again being careful not to bend or
otherwise damage the connecting rods.
2)
Replace left and right side bearings (12A and 12B), if they were removed from the crankshaft. Be
certain the bearings are pressed all the way onto the shaft and completely into the crankcase.
Replace radial shaft seal (11) bearing cover with sight glass (7 and 8) and crankcase cover with O-
ring (3 and 4).
3)
If oil seals (19) were removed, replace with seal lip towards crankcase. Lubricate seal with silicone
grease before replacing.
4)
Replace seal case (20) with O-ring (21) over plungers. Generously lubricate O-ring and oil seal
With silicone grease before reassembly. Replace V-sleeve (23) over plunger.
5)
Generously lubricate V-sleeve (23). Assemble spacer and V-sleeve (23) into valve casing (26).
Assemble weep return ring and pressure ring (25 and 24) over plungers. Slide the valve casing over
plungers and seat firmly. Replace the eight-socket head cap screws (34) and tighten to 105 inch
pounds in a crossing pattern.
6)
Replace the six O-rings (31) and the six-valve assemblies (32X). Replace the six valve plugs with
O-rings (32 and 33) and tighten securely with a 22mm socket wrench to 33 foot-pounds.
7)
Fill crankcase with 7.5 ounces / 0.22 ltr of non-toxic, non-detergent SAE 90 gearbox oil.
