Section 5
Service Procedures
72183211
8-2016/Rev 01
ORIGINAL INSTRUCTIONS
5-45
7.
Loosen the left hand threads on the plunger adapter and remove the adapter from the tool
cap.
8.
Remove the plunger from the plunger adapter.
9.
Place the tool cap on a workbench with the seal bore facing up.
10.
Remove and discard the existing backup ring, oil seal and o-ring.
11.
Clean the tool cap and ensure it is free of burrs or any defects.
12.
Ensure the new components are clean and place the
o-ring on the oil seal. Apply FML-2 food grade
grease to the o-ring and insert the seal into the bore in
the tool cap until fully seated.
13.
Seat the backup ring against the oil seal.
14.
Place the tool cap in a soft jaw vise with the oil seal facing up.
15.
Inspect the threads on the plunger and plunger adapter. Repair or replace as necessary.
16.
Apply JL-M anti-seize grease to the male threads on the plunger and the female threads in
the bore of the plunger adapter. Thread the plunger into the adapter.
17.
Apply Loctite 242 to the male, left hand threads on the plunger adapter and thread the
adapter into the tool cap until fully seated.
18.
Using a torque wrench and a 1-1/4-inch crowfoot wrench, torque the adapter to 80 ft-lbs
(108 Nm).
19.
Remove the tool from the vise.
20.
Rotate the plunger clockwise to ensure the plunger is extended through the seal bore and
there is sufficient access to the female threads on the end of the plunger.
21.
Turn the assembly over and grip the plunger hex in the vise.
22.
Place the stop cap on the end of the plunger. Apply Loctite 242 to the left hand threads on
the screw, thread the screw through the stop cap and torque to 40 ft-lbs (54 Nm).
23.
Remove the tool from the vise, turn the assembly so the piston bore faces up and place the
assembly back in the vise.
24.
Install the new backup ring and o-ring in the external piston groove.
The backup ring is directional shaped. Ensure the o-ring is seated against the
radius side of the backup ring.