Hydraulic Hand Pump
Care and Maintenance
Page 21
19. Once the Inner Leather Cup #2H has started going into the Sealant Barrel #3 wipe all of the remaining
Piston Assembly #2 with hydraulic fluid then push the Piston Assembly #2 into the Sealant Barrel #3.
IMPORTANT: use the Handle #10 to push the Piston Assembly #2 back and forth
several times to help break the new parts in.
20. Place the Handle #10 so it is centered on the Piston Assembly #2 then push the Piston Assembly #2 so
the Inner Leather Cup #2H is level with the o-ring end of Sealant Barrel #3.
21. Remove the Sealant Barrel #3 from the pipe vise and place the Pump Body Assembly #4 vertically into
the pipe vise as it was previously.
22. If required, replace the Barrel Gasket #3A and the Barrel O-Ring #3B with new parts.
23. Thread the end of Sealant Barrel #3 into the Body Assembly #4. Once you feel the Sealant Barrel #3
makes contact with the Barrel O-Ring #3B, back off the Sealant Barrel #3 one-half (½) turn.
24. Place Handle #10 into the Fulcrum #9 and stroke the pump until hydraulic fluid is seen leaking at the
threads.
If no fluid is detected after a few strokes, back off the Sealant Barrel #3 an additional ½ turn and
stroke the pump again. Repeat this until hydraulic fluid is detected leaking at the threads.
25. Tighten the Sealant Barrel #3 and wipe the pump clean of the leaked hydraulic fluid.
26. Open the By-Pass Valve #7.
27. Use the Handle #10 to push the Piston Assembly #10 completely to the end of the Sealant Barrel #3.
28. Close the By-Pass Valve #7.
29. Reattach the Handle Latch Assembly #16.
Follow steps 1 through 8 of
“To reassemble the Handle Latch Assembly”
in the
“Handle
Latch Repair and Replacement”
instructions on page twenty-six (26).
30. To refill the hydraulic system, continue on step seven (7) under “
Bleeding and Filling the Hydraulic
Fluid Bag”
on page fourteen (14).
Pump Piston Cartridge Repair and Replacement
A worn Pump Piston #5C and Hydraulic Pump Cylinder #5 can be easily detected when the Handle #10 travels
freely down before you feel the force of the hydraulic fluid. The more it travels without any force, the more they
are worn. The more worn they are, the longer it will take to service a valve. It is recommended that the assembly
be replaced if the Handle #10 can travel more than half its swing before feeling the pressure of hydraulic fluid.
Carefully examine the Linkage Assembly #11 and the Pump Piston #5C as you stroke. A worn Linkage Assembly
#11 can be misinterpreted as pump piston cartridge wear.
Follow these instructions:
1. Open By-Pass Valve #7; check the 15,000 PSI Gauge #17B to make sure all internal pressure is
relieved from the system.
2. Remove head assembly (Sealant Barrel Cap #1 and Hydraulic Pump Hose Assembly #17) from Sealant
Barrel #3.
3. Remove the Handle #10 from the Fulcrum Assembly #9 and clean off any contaminants such as sand or
dirt.
4. Place the Handle #10 so it is centered on the Piston Assembly #2 then push the Piston Assembly #2 to
the bottom of the Sealant Barrel #3.
NOTICE: be very careful not to scratch or score the inside of the Sealant Barrel #3.
