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11
Replacing the Gears and/or Slider Assembly
1. Using a Phillips screwdriver, remove the four front cover
screws. Remove the front cover.
2. Start the engine (refer to the procedures in the Operation
section of this manual). Turn the pressure control knob
clockwise to its maximum pressure setting.
3. Toggle the sprayer ON/OFF switch between the ON and OFF
positions in short bursts until the slider assembly and piston
stop at the bottom of their stroke (in their lowest position).
4. Turn off the engine and perform the Pressure Relief Procedure.
NOTE: If replacing the slider assembly, the fluid section
must be removed from the pump housing.
Pump
Housing
Slider
Assembly
Front
Cover
Screw
Front
Cover
Fluid
Section
Housing
Piston
Socket
Screw
5. Using a 3/8” hex wrench,
remove the two socket
screws that secure the
fluid section to the pump
housing.
6. Pull fluid section housing
down approximately
1/2” from the gear box
housing to clear the
transducer.
7. Slide the fluid section
housing and piston rod
forward until the piston
rod is out of the T-slot on
the slider assembly.
8. Using a 1/4” hex
wrench,remove the four socket screws that secure the pump
housing to the gear housing.
Gear Housing
Crankshaft
Assembly
Cylindrical
Thrust Washer
Thrust
Washer
Slider Bushing
Pump Housing Socket Screw
Thrust Washer
Output Gear Assembly
Thrust Washer
Housing Gasket
Pump Housing
Slider Assembly
9. Slide the pump housing away from the gear housing.
10. Remove and clean the housing gasket. Replace if damaged.
11. Slide the crankshaft assembly, with the two thrust washers out
from the gear housing side of the pump housing.
12. Remove the output gear assembly with the two thrust
washers.
13. Thoroughly clean the crankshaft assembly, the output gear
assembly, and all the thrust washers.
14. Inspect all parts for excessive wear and replace if damaged or
worn. If the crankshaft or output gear assembly are replaced,
replace the corresponding thrust washers as well.
15. Inspect the pinion gear on the end of the drive shaft for wear.
Replace if damaged or worn (refer to the “Servicing the Clutch
Assembly” procedure in this section).
NOTE: If any of the gears are worn and require
replacement, check the grease in the gear housing
for metal particles or shavings. Remove the
contaminated grease. Replace the grease that has
been removed with fresh Lubriplate GR-132 grease.
16. Slide the slider assembly up and out of the slider bushing in
the front of the pump housing.
17. Check the parts for wear.
a. If the slider bushing is scored or out of round the pump housing
should be replaced.
b. If the slider assembly is scored or the connection between the
connecting rod and slider assembly exhibits movement other than
pivoting movement, the slider assembly should be replaced. The
slider assembly also should be replaced if the connecting rod bearing
shows signs of wear.
c. Any parts that will be reused should be cleaned thoroughly,
including the connecting rod. Also, clean the crankshaft pin that the
connecting rod bearing rides on.
18. Coat the output gear assembly and each side of its thrust
washers with fresh Lubriplate GR-132 grease. Place the thrust
washers on their proper shaft of the output gear assembly.
19. Lubricate the output gear assembly with fresh Lubriplate GR-
132 grease. Insert the gear assembly into its bore in the gear
housing, gear end first. The teeth on the gear will mate with
the teeth on the drive shaft pinion.
20. Generously coat all surfaces of the cylindrical crankshaft
assembly thrust washer with fresh Lubriplate GR-132 grease.
21. Slip the flat end of the cylindrical thrust washer behind the
gear on the output gear assembly, lining its bore up with the
gear housing bearing bore for the crankshaft assembly.
22. Lubricate the crankshaft assembly gear with fresh Lubriplate
GR-132 grease. Slide the gear side shaft of the crankshaft
through the cylindrical thrust washer and into its bore within
the gear housing.
23. Position the pin on the end of the crankshaft towards
the bottom of the gear housing (the bottom dead center
position).
24. Lubricate both faces of the large crankshaft assembly thrust
washer with fresh Lubriplate GR-132 grease. Place the thrust
washer onto the crankshaft against the gear.
25. Place the housing gasket over the gear housing dowel pins.
26. Lubricate the outside of the slider assembly and the inside of
the slider bushing with oil. Fill the slider cup with Lubriplate
1242 grease (the slider cup is the area on the slider assembly
where the connecting rod and slider join and pivot).
27. Insert the slider assembly into the slider bushing.
28. Carefully place the pump housing assembly in front of the
gear housing assembly, lining up the gear housing dowel pins
with their corresponding holes in the pump housing. Slide
the pump housing onto the gear housing until there is no gap
between the housings and gasket.
NOTE: While sliding the pump housing into place, the
crankshaft pin will begin to protrude from the
bearing in the center of the pump housing. Position
the slider assembly so that as the crankshaft pin
protrudes from the main bearing, it engages the
connecting rod bearing.
ImPORTANT: Do not force the pump housing and gear housing
together.
29. Locate the four socket screws and lock washers that secure
the pump housing to the gear housing.
30. Using a 1/4” hex wrench, snug and tighten the socket screws
in a crossing pattern. Torque to 200–230 in./lbs.
31. Slide the top of the piston rod into the T-slot on the slider
assembly.
32. Position the pump block underneath the gear box housing
and push up until it rests against the gear box housing.
33. Insert the two socket screws that secure the fluid section to
the pump housing and alternately snug, tighten, and torque
the screws to 400-440 in./lbs.
34. Position the front cover over the pump housing. Secure the
front cover using the four front cover screws.
