11
824–001
804–544 Pump Service
WARNING
To reduce the risk of serious bodily injury, including
fluid injection, splashing in the eyes or on the skin,
or injury from moving parts, always follow the
Pressure Relief Procedure Warning on page 5
before proceeding.
NOTE:
The following metric wrenches are needed: 5
mm, 13 mm and 22 mm. Repair kits are
available. Refer to the individual repair
sections and the pump parts page for more
details. For the best results, use all parts in
the kits.
NOTE:
There is a tool kit to aid in servicing the
pump. P/N 800–271 includes tools to aid in
the removal of packing retainers.
Valves
NOTE:
For a set of six valves, order P/N 801–472.
1.
Remove the hex plug from the manifold using a 22
mm socket.
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 33 ft–lb (45 N
m).
NOTE:
Retorque the plug after 5 hours of operation.
Pumping Section
1.
Remove the eight capscrews and lockwashers
from the manifold using a 5 mm wrench.
2.
Carefully separate the manifold from the
crankcase.
NOTE:
It may be necessary to tap the manifold
lightly with a soft mallet to loosen.
CAUTION
Keep the manifold properly aligned with the ce-
ramic plungers when removing to avoid damage to
the plunger or seals.
3.
Carefully examine each plunger for any scoring or
cracking and replace as necessary.
Servicing the Plungers
NOTE:
Plunger repair kit, P/N 801–474 is available
to replace retainers, o–rings, washers and
backup rings for three cylinders.
1.
Loosen the plunger retaining nut five to six turns,
using a 13 mm wrench. Push the plunger towards
the crankcase to separate the plunger and
retaining screw.
2.
Remove the nut from the plunger and examine the
o–ring, backup ring and copper bearing/gasket
washer. Replace these parts, if necessary, using
kit 801–474.
3.
Remove the plunger and flinger from the plunger
shaft. Clean, examine and replace parts as
necessary.
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 as
they cannot be reused. An oil seal kit is available
to replace the seals.
5.
Lightly grease the flinger and oil seal, if it is being
replaced and replace them on the plunger shaft.
Then install the plunger.
