21
English
Fluid Section Seal Replacement Instructions
Kit Part number 0516701 (XL255, XL295)
Kit Part number 0516700 (XL335)
Always wear protective eye wear while servicing the pump. Be sure to follow the Pressure Relief Procedure
(page 7) when shutting the unit down for any purpose, including servicing or adjusting. After performing
the Pressure Relief Procedure, be sure to unplug the unit before servicing or adjusting. Area must be free of
solvents and paint fumes.
Disassembly of the Fluid Section
1. Remove the suction set.
2. Remove the front cover and the three
screws that secure it using a T20 Torx
head driver.
3. Remove the yoke screw and washer
that secures the dowel pin. The dowel
pin connects the yoke to the piston.
4. Using a pliers, pull the dowel pin out.
5a.
For models XL255 and XL295
, rotate the pump shaft
so the piston is in the top dead center position. This
can be done by pushing on the yoke. This is required to
disassemble all the parts.
5b.
For model XL335
, inspect the yoke assembly and piston.
In order to remove all the necessary parts, the piston
must not be in the bottom dead center position. If the
piston is at the bottom of the stroke, install the front cover
and screws, turn the pump on briefly to index the piston,
unplug the unit, and repeat step 2.
6. Unscrew and remove the Quickflo™ valve assembly (see
page 20).
7. Remove the piston assembly by pushing down on the
piston near the yoke.
8. Unscrew and remove the top nut using and adjustable wrench.
9. Remove the worn seals using a flat head screwdriver or
punch. Remove the top seal from the top and the bottom
seal from the bottom by pressing against the side of
the seal and popping it out. Be sure not to scratch the
housing where the seals are located.
10. Clean the area where the new seals are to be installed.
Assembly of the Fluid Section
1. Lubricate the new top seal with Separating Oil (P/N
0516444, sold separately) or light household oil and by
hand place the seal (cup side of seal down) into the top
port of the housing.
2. Place a small amount of anit-seize on the threads of the
top nut. Place the top nut into the top of the housing and
tighten with an adjustable wrench. This will drive the top
seal into the correct position.
3. Turn the pump upside down.
Lubricate the seal on the piston/
seal assembly similar to the
top seal. Place the piston/seal
assembly into the bottom of the
housing. Insert the plastic insertion
tool and thread into position to
properly seat the piston/seal.
Thread fully until tight. Remove the
insertion tool.
4. Install the new O-ring on the inlet valve assembly, lubricate
with Separating Oil (P/N 0516444, sold separately) or light
household oil, thread into the bottom (inlet) of the housing,
and tighten with an adjustable wrench. This will drive the
bottom seal into the correct position.
5. Align the piston with the yoke. Be careful not to damage
the piston.
6. Apply a lithum grease to the holes in the yoke where the
dowel is inserted.
7. Install the dowel pin to connect the yoke to the piston.
The piston may have to be moved up or down to do this.
The inlet valve may need to be removed again to move
the piston.
8. Install the yoke screw and washer to secure the dowel pin.
9. Turn pump right side up and apply a few drops of
Separating Oil (P/N 0516444, sold separately) or light
household oil between the top nut and piston. This will
prolong the seal life.
10. Install front cover and three (3) screws.
11. Install the Quickflo™ valve assembly. Install the suction
set.
Insertion
tool
0516700 Kit
(XL335)
0516701 Kit
(XL255 and
XL295)
Top seal
(cup down)
Top nut
0516700 Kit
(XL335)
0516701 Kit
(XL255 and
XL295)
Piston/seal
assembly
O-ring
NOTE - DO NOT
attempt to remove the
seals from the piston.
Quickflo™ valve assembly
Dowel
Yoke
Screw
Washer
