27
308–530
4. With crankcase side of manifold down remove
hi–pressure seals using a reverse pliers.
5. Invert manifold so crankcase side is up and with
reverse pliers remove low pressure seals.
Reassembly:
1. Examine low pressure seal for seal wear or spring
failure and replace if necessary. With crankcase side
of inlet manifold up, lubricate seal and press into
valve chamber with garter spring down. Carefully
square seal into position.
2. Examine hi–pressure seal for wear and replace if
necessary. Invert inlet manifold with crankcase side
down, lubricate seal and press into chamber with
v–side up. Carefully square into position.
3. Rotate shaft so the two (2) outside plungers are
extended and lined–up.
4. Lubricate plungers and discharge valve adapter
o–rings.
5. Carefully line–up and
join the inlet and discharge
manifolds by pressing the protruding discharge valve
adapters into the inlet manifold seal chambers.
6. Replace all four (4) discharge manifold socket head
bolts and washers and hand tighten.
7. Then carefully slip manifold assembly onto plungers
and tap with soft mallet until flush with crankcase.
8. Replace the two (2) inlet manifold socket head bolts
and washers and hand tighten. Then torque per
chart.
9. Then torque the four (4) discharge manifold socket
head bolts per chart.
Servicing the Plungers
Disassembly:
1. Remove discharge and inlet manifold as described.
2. Using a wrench loosen plunger retainers
approximately three (3) to four (4) turns.
3. Grasp ceramic plunger and push towards crankcase
until plunger retainers with stud pop out.
4. Remove plunger retainer and copper gasket.
5. Remove ceramic plunger from plunger rod.
6. Remove barrier slinger from plunger rod.
Reassembly:
1. Replace barrier slinger if necessary and
position
onto plunger rod.
2. Carefully examine ceramic plunger for scoring or
cracks and replace if worn. Slip onto rod.
NOTE:
Ceramic plunger can only be installed one
direction (front to back). Do not force onto rod.
3. Examine o–ring and back–up ring on plunger
retainer and replace if worn or cut. Lubricate o–ring
for ease of installation and to avoid damage to
o–rings.
NOTE:
First install NEW copper gaskets on plunger
retainers, then back–up rings and o–rings.
4. Install short threaded end of stud into plunger
retainer.
5. Thread plunger retainer and stud assembly into
plunger rod and torque per chart. (Long threaded end
of stud into plunger rod.)
NOTE:
Exercise caution not to over torque the plunger
retainer.
6. Rotate shaft so the two (2) outside plungers are
extended and lined–up. Then lubricate plungers.
7. Replace all four (4) discharge manifold socket head
bolts and washers and hand tighten.
8. Then carefully slip manifold assembly onto plungers
and tap with soft mallet until flush with crankcase.
9. Replace the two (2) inlet manifold socket head bolts
and washers and hand tighten. Then torque per
chart.
10. Then torque the four (4) discharge manifold socket
head bolts per chart.
Servicing Crankcase Section
1. While inlet manifold, plungers and seal retainers are
removed, examine crankcase seals for wear.
2. Check oil level and for evidence of water in oil.
3. Rotate crankshaft by hand to feel for smooth bearing
movement.
4. Examine crankshaft oil seal externally for drying,
cracking or leaking.
5. Consult factory or your local distributor if crankcase
service is required.
Torque Chart
Pump Part
Thread Tool Size Torque
Plunger Retainer M5
11 mm hex 80 in. lbs.
Inlet Manifold
Bolts
M10
8 mm allen 132 in. lbs.
Discharge
Manifold Bolts
M10
8 mm allen 180 in. lbs.
