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DC-1600N REPAIR KIT INSTRUCTIONS & ORDER NUMBERS

Always wear protective eye wear while servicing the pump. Be sure
to follow the Pressure Relief Procedure 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 (DC1600 & DC1600N)
1) Remove the suction set.
2) Remove the front cover and the four 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.
5) 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.

6) Unscrew and remove the inlet valve assembly.
7) Remove the piston assembly by pushing down on the

piston near the yoke.

8) Unscrew and remove the top nut using an 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 L034-125) or

light household oil and then by hand place the seal (cup side of seal
down) into the top port of the housing.

2) Place a small amount of anti-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 L034-125), 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 any type of household grease to the piston and yoke area to

prolong life. Apply 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.

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 or

light household oil between the top nut and piston. This will prolong
the seal life.

10) Install front cover and four (4) screws.
11) Replace inlet valve. Install the suction set.

L045-382
Pump
repair kit

L045-387
Cleaning adapter

L045-386
Clamp

L045-648
Clip

L045-383
Suction set