ZEP N83701, Service Manual

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Pump Maintenance
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General
PACKING EXTRACTION KIT P/N Z09-00028
COMPLETE TOOL KIT P/N Z09-00021
Valve Service
1. Remove the plugs holding the valve assemblies.
2. Remove and discard o-rings from the plugs. Clean plugs with solvent or soap and water. Allow to
dry.
3. Using needle nose pliers, fingers, or hook shaped tool, remove the valve assemblies from the head.
Remove and discard the o-rings from the valve assemblies and/or head. Examine each valve
assembly and discard damaged parts. Refer to the PUMP BREAKDOWN for part numbers of any
replacement items.
4. Clean any accumulated debris from the valve cavities and flush with water.
5. Wash the valve assemblies in clean water and rinse. While still wet, test each valve assembly by
sucking on the valve seat. A properly sealing valve will allow a good vacuum to be developed and
maintained, while a malfunctioning valve will not. Good valve assemblies should be set aside for
installation in step 7.
6. Malfunctioning valve assemblies must be replaced.
7. Lubricate a new o-ring with the pump crankcase oil and install into valve cavity in the head. Install a
good valve assembly into the cavity as illustrated.
8. Lubricate a new o-ring with pump crankcase oil and place on a plug cleaned in step 2 above.
9. Install a plug into the pump head. Tighten plug by hand.
10. Torque the plug to the value indicated in the TORQUE section of the pump specifications.
11. Repeat steps 7 through 11 for remaining valve assemblies.
Head Removal
1. Remove the cap screws holding the pump head to the crankcase. A metric tool is required for this
step. Be careful not to lose the washer on each cap screw.
2. Remove the head by rotating the crankshaft and tapping the head away from the crankcase with a
soft mallet. Keep rear surface of the head parallel to the front surface of the crankcase to prevent
binding on the plungers.
3. Once the head is removed, protect the plungers from damage.
Pump Maintenance