Machine Maintenance: 4-6
5. Replace old valves with new valves by placing the assembly in the valve chamber.
Press down firmly on the top of the valve assembly.
6. Replace valve caps by applying LOCTITE® 243 to valve cap and torque to 33 ft-
lbs.
Removing and Replacing Pump Manifold
1. Remove the manifold of the pump by taking a 5-mm Allen head wrench and removing
the eight head bolts.
2.
With the pump firmly secured, take a medium sized flat head screwdriver and apply
pressure to the manifold by prying between the crankcase and manifold. Work
around from all sides of the manifold evenly until it comes off of the pistons. Keep
the manifold properly aligned with the pistons to prevent damage to the seals and
pistons.
3. When replacing the manifold, turn the crankshaft of pump until the top of the pistons
are closely aligned. Lubricate the pistons and cylinders with grease and evenly
press the manifold toward crankcase until flush.
Seals and V-Packing Maintenance
1. Remove the manifold as previously described. It is possible that the seal and brass
retainer ring assembly will stay on the piston or will remain in the manifold when
removing it.
2. Carefully remove the brass retainer ring/seal stack. Remove the low-pressure seal
using needle nose pliers. Discard the old seal.
3.
Remove the outer O-ring by taking a small flat head screwdriver and working it
under the O-ring. Simply roll off the old O-ring and discard.
4. The old V-packing stack can be taken apart by hand and discarded.
Seals and V-Packing Reassembly
1. Generously lubricate parts with grease when reassembling. Examine all brass
components for any damage or water residue build-up. Clean or replace as
needed.
2. Insert a new low pressure seal by working it in by hand.
3. Install the new outer O-ring by simply starting on one side and working it into the
groove.
4.
Stack the new V-packing in the correct order and firmly press the assembly into the
manifold.
5. Install a new low pressure oil seal by laying the seal into the opening and evenly
pressing it into place.
6. Re-install the manifold onto the pump as previously described.
Summary of Contents for CTS 403 Flex
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