6
Repairs & Major Service
P U M P A S S E M B LY
The pump assembly includes items 29, 35, 36, 37, 49, 51 and one of the following plunger seal combinations, either seals
(37 and 50 2 off) or (37, 84 and 85). These parts are only available fully assembled as a complete Pump Assembly Kit (part
number 71600-99601), unless the individual part numbers are provided in the parts list.
•
Completely remove the main internal mechanism from the left and right mouldings 41, 43, as described on page 5.
•
To gain access to the pump attachment screws 29 the trigger assembly, items 34, 40, must be removed. Using the circlip
pliers remove one circlip 67 from pin 66. Push the pin out allowing the trigger lever 34 and trigger button 40 to be removed.
•
Hold the main internal mechanism and pump block 51 securely in position and using the 3 mm allen key remove the four
attachment screws 29. Remove the complete pump assembly from the housing 24. Care must be taken when removing
the pump assembly as the plunger 36 will be spring loaded.
•
Remove the plunger 36 and spring 35 from the pump block 51 taking care not to damage the seals, plunger surface and
the pump block bore.
•
Remove ‘O’ ring 49 from housing 24 and discard.
Assemble in reverse order to dismantling noting the following points:
•
Clean the plunger 36 and apply a small amount of Molykote 111 grease to the seals using the spatula.
•
Clean the pump block 51 bore and then lubricate with Molykote 111 grease using the spatula.
•
Place spring 35 over the sealed plunger, align the end of the plunger with the pump block 51 bore and push into place
until the seals are no longer visible. When inserting the plunger take care not to damage the seals on the rim of the pump
block bore.
•
Apply a light film of Loctite
®
243 threadlocker to all four screws 29.
•
Attach the pump assembly onto the housing 24 as before using four screws 29 and the 3 mm allen key.
•
Finally assemble the trigger assembly, items 34, 40, and pin 66 in reverse order to dismantling.
The motor, gearbox and electrical assembly includes items 3, 4, 5, 28, 38 and 52. These parts are only available as a
complete assembly (part number 71600-99602), unless the individual part numbers are provided in the parts list.
•
Completely remove the main internal mechanism from the left and right mouldings 41, 43, as described on page 5.
•
Remove the ‘pump assembly’ as described above.
•
Using the small screwdriver remove the two screws 28 that retain the micro-switch to the switch bracket 27.
•
Using the 3 mm allen key remove all three screws 38 and washers 52 attaching the gearbox to the housing 24.
•
Remove the complete motor, gearbox and electrical assembly 3, 4 and 5 from the housing 24.
Assemble in reverse order of dismantling noting the following points:
•
Ensure that the motor and gearbox assembly, when connected to the housing 24, is orientated so that the groove in the
gearbox mounting plate is at the top.
•
Apply Loctite
®
243 threadlocker to all three screws 38.
•
DO NOT USE UNDUE FORCE when inserting the three screws 38 into the housing 24.
M O T O R , G E A R B O X A N D E L E C T R I C A L A S S E M B LY
