10 309880
Pump Service
Repair kits are available. See
Pump Repair Kits
on page 15. For the best results, use all parts in the kits.
Relieve the pressure
(see page 5) before you
proceed with service.
NOTES:
D
The following metric wrenches are needed:
10 mm, 13 mm, and 30 mm.
Valves
NOTE:
For a set of six valves, order 801472.
1.
Remove the hex plug from the manifold using a
30 mm wrench.
2.
Examine the o-ring under the hex plug and replace
it if it is cut or distorted.
3.
Remove the valve assembly from the cavity; the
assembly may come apart.
4.
Install the new valve. Install the o-ring and hex
plug; torque to 75 ft-lb (103 N
S
m).
NOTE:
Retorque the plug after 5 hours of operation.
Pump Section
1.
Remove the eight capscrews and lockwashers
from the manifold using a 13 mm wrench.
2.
Carefully separate the manifold from the crank-
case.
NOTE:
You might have to tap the manifold lightly with
a soft mallet to loosen it.
CAUTION
To avoid damage to the plunger or seals, keep the
manifold properly aligned with the ceramic plungers
when you remove it.
3.
Carefully examine each plunger for any scoring or
cracking, and replace as necessary.
Servicing the Plungers
NOTE:
Plunger repair kit 801474 is available to re-
place retainers, o-rings, washers, and backup rings for
three cylinders.
1.
Loosen the plunger retaining screw five to six
turns. Push the plunger towards the crankcase to
separate the plunger and retaining screw.
2.
Remove the screw from the plunger, and examine
the o-ring, backup ring, and copper bearing/gasket
washer. Replace these parts, if necessary.
3.
Remove the plunger and flinger from the plunger
shaft. Clean, examine, and replace parts as neces-
sary.
4.
Inspect the plunger shaft for oil leakage from the
crankcase. If leaking is obvious, replace the oil
seals. Otherwise, DO NOT remove these seals
because they cannot be reused. Oil Seal Kit
801473 is available for replacing the seals.
5.
Lightly grease the flinger (and the oil seal if it is
being replaced), and replace on the plunger shaft.
Then install the plunger.
