16
© Titan Tool Inc. All rights reserved.
Piston Rod
Lower
Packing
Assembly
Cylinder
Upper
Seal
Retainer
Adapter
Ring
Upper
Packing
Assembly
Jam nut
Outlet Valve
Seat
Nylon Washer
Outlet Cage
Outlet Valve
Ball
Outlet Valve
Seal
Outlet Valve
Retainer
14. Using a wrench, remove the
upper seal retainer.
15. Slide the piston rod out through
the bottom of the cylinder.
16. Inspect the piston rod for wear
and replace if necessary.
17. Remove the adapter ring and
upper packing assembly from
the top of the cylinder.
18. Remove the lower packing
assembly from the bottom of the
cylinder.
NOTE: Be careful not to scratch,
score, or otherwise
damage the cylinder
during removal of the
packing assemblies.
19. Remove the cylinder from the
vise.
20. Insert the connection pin through
the hole at the top of the piston
rod and clamp each end of the
connecting pin in the vise. This
will hold the piston rod in position
for disassembly.
NOTE: Do not clamp the piston
rod directly in the vise.
Damage to the piston rod
will occur.
21. Using a 3/8” hex wrench, loosen
and remove the outlet valve
retainer from the piston rod.
22. Remove the outlet valve seal,
outlet cage, outlet valve ball,
nylon washer, and outlet valve
seat from the outlet valve retainer.
23. Clean out any debris and examine the retainer and outlet
valve seat. If the seat is damaged, reverse to the unused
side or replace the seat.
24. Clean and inspect the outlet cage and outlet valve ball.
Replace if they are worn or damaged.
25. Reassemble the outlet valve assembly into the piston rod
in the reverse order of how it was disassembled. Use the
new parts supplied with the packing kit during reassembly.
Apply blue Loctite #242 to the threads of the outlet valve
retainer. Torque the outlet valve retainer to 144 in./lbs.
26. Remove the piston rod from the vise.
27. Clean the cylinder. Inspect the cylinder for damage and
replace if necessary.
28. Place the cylinder upright in a vise by clamping on the
wrench flats.
29. Locate the new upper and lower packing assemblies and
pack the areas between the packing lips with grease.
Lubricate the o-rings on the exterior of the packings with
grease.
Install upper packing
with large beveled
edge facing down.
Large Beveled Edge
30. Insert the upper packing
assembly into the top of the
cylinder with the large beveled
edge facing down.
31. Insert the new adapter ring into
the top of the cylinder with the
small, center protrusion facing
down. The adapter ring should
rest on the upper packing
assembly.
32. Apply blue Loctite #242 to the threads of the upper seal
retainer. Thread the upper seal retainer into the cylinder
but do not tighten.
33. Rotate the cylinder in the vise so that the bottom end is
facing up.
34. Pre-form the lower packing using the lower packing sizing
tool (included in the repacking kit).
Install lower packing so
large beveled edge will
be facing up when the
cylinder is upright.
Large Beveled Edge
35. Insert the lower packing
assembly partially into the
bottom of the cylinder with
the large beveled edge facing
toward the cylinder (beveled
edge will be facing up when
the cylinder is upright).
36. Push the lower packing
assembly into position
using the lower packing insertion tool (see Fluid Section
Assembly parts list for lower packing insertion tool P/N).
37. Place the piston insertion tool (included in the repacking
kit) over the top of the piston rod.
38. Insert the piston rod into the bottom of the cylinder,
through the lower packing assembly, through the upper
packing assembly, and out through the upper seal
retainer.
39. Tighten the upper seal retainer. Torque to 450–480 in./lbs.
NOTE: When repacking the fluid section, make sure the
raised lip on the bottom of the lower packing
assembly is fully outside the packing around the
piston rod after insertion of the piston rod.
40. Apply blue Loctite to the bottom 3–4 threads on the
cylinder. Turn the jam nut clockwise until it is flush against
the top of the cylinder.
41. Lubricate the first several threads at the top of the cylinder
with anti-seize compound. Remove the cylinder from vise.
42. Thread the cylinder into the pump housing, turning
clockwise. When the connecting pin hole on the piston
rod lines up with the hole in the slider assembly, insert the
connecting pin.
43. Slide the retaining ring down on the slider assembly to
cover the connecting pin.
44. Continue to turn the cylinder clockwise until the jam nut is
flush against the pump housing.
NOTE: If the nipple on the cylinder does not face the back
of the unit, turn the cylinder counterclockwise
until the nipple faces the back of the unit. Do not
turn the cylinder more than one full turn.
45. Once the nipple is positioned, turn the jam nut clockwise
until it contacts the pump housing.
46. Tighten the jam nut with a wrench to tighten it against the
pump housing. Torque to 960-1000 in./lbs.
47. Attach the high-pressure hose to the fitting on the back
of the cylinder and tighten with a wrench. Do not kink the
hose.
48. Install new Teflon o-ring onto lower housing. Thread lower
housing into upper housing cylinder. Torque to 680-720
in./lbs.
49. Making sure that the new Viton o-ring and new Teflon
back-up ring are lubricated and in place, reassemble
the inlet valve assembly and thread it into the cylinder.
Use the new parts supplied with the packing kit during
reassembly. Tighten the inlet valve housing until the
o-ring engages, then continue to tighten until snug.
50. Using a wrench, hold the cylinder by the wrench flats and
torque the inlet valve housing to 1020–1080 in./lbs.
51. Place the front cover on the pump housing and secure in
position using the four front cover screws.
52. Turn on the sprayer by following the procedure in the
“Operation” section of this manual and check for leaks.
NOTE: Repacking kit P/N 0555222 is available. For best
results use all parts supplied in this kit.
