20. Remove the cylinder from the
vise.
21. Insert the connection pin
through the hole at the top of
the piston rod and clamp each
end of the connecting pin in
the vise. This will hold the
piston rod in position for
disassembly.
22. Using a 3/8” hex wrench,
loosen and remove the outlet
valve retainer from the piston
rod.
23. Remove the outlet valve seat,
outlet valve ball, nylon washer,
outlet valve cage, and outlet
valve seal from the piston rod.
24. Clean out any debris and
examine the retainer and outlet
valve seat. If the seat is
damaged, reverse or replace
the seat.
25. Clean and inspect the outlet
valve cage and outlet valve
ball. Replace if they are worn
or damaged.
26. Reassemble the outlet valve
assembly into the piston rod in
the reverse order of how it was
disassembled. Torque the
outlet valve retainer to 12 ft. lbs.
27. Remove the piston rod from
the vise.
28. Clean the cylinder. Inspect the
cylinder for damage and
replace if necessary.
29. Place the cylinder upright in a
vise by clamping on the wrench flats.
30. Locate the new upper and lower packings and remove the
pre-form tools. Save the upper packing pre-form tool for
use as the piston insertion tool later in this procedure.
31. Pack the areas between the
packing lips with grease.
Lubricate the o-rings on the
exterior of the packings with
grease.
32. Insert the upper packing into the
top of the cylinder with the
raised lip on the packing facing
down toward the cylinder.
33. Insert the upper support ring on top of the upper packing.
34. Thread the upper seal retainer
into the cylinder and torque to
25-30 ft. lbs.
35. Rotate the cylinder in the vise so
that the bottom end is facing up.
36. Insert the lower packing partially
into the bottom of the cylinder
with the large beveled edge
facing toward the cylinder
(beveled edge will be facing up
when the cylinder is upright).
Large Beveled Edge
Install lower packing so
large beveled edge will
be facing up when the
cylinder is upright.
Install upper packing
with raised lip
facing down.
Raised Lip
NOTE: Do not remove the pre-form tools from the
upper and lower packings until immediately
before they are installed into the cylinder.
NOTE: Do not clamp the
piston rod directly
in the vise. Damage
to the piston rod will
occur.
Piston Rod
Cylinder
Upper
Seal
Retainer
Upper
Packing
Assembly
Adapter
Outlet Valve
Seal
Outlet Valve
Cage
Nylon
Washer
Outlet Valve
Ball
Outlet Valve
Seat
Outlet Valve
Retainer
Upper
Support
Ring
Lower
Packing
Assembly
37. Push the lower packing assembly into position using the
lower packing insertion tool (see Fluid Section Assembly
parts list for lower packing insertion tool P/N).
38. Place the piston insertion tool over the top of the piston
rod.
39. Insert the piston rod into the bottom of the cylinder,
through the lower packing assembly, through the upper
packing assembly, and out through the upper seal
retainer.
40. Remove the piston insertion tool from the top of the piston
rod.
41. Turn the jam nut counterclockwise until it is flush against
the top of the cylinder.
42. Lubricate the threads on the cylinder with anti-seize
compound. Remove the cylinder from the vise.
43. Thread the cylinder into the gear box housing, turning
clockwise. When the connecting pin hole on the piston
rod lines up with the hole in the slider assembly, insert the
connecting pin.
44. Slide the retaining ring down over the connecting pin.
45. Continue to turn the cylinder clockwise until the jam nut is
flush against the gear box housing.
46. Once the nipple is positioned, turn the jam nut clockwise
until it contacts the gear box housing.
47. Tighten the jam nut with a wrench to tighten it against the
gear box housing.
48. Attach the high-pressure hose to the nipple on the back of
the cylinder and tighten with a wrench. Do not kink the hose.
49. Insert the adapter into the bottom of the cylinder.
50. Making sure that the Viton o-ring and
PTFE
back-up ring
are lubricated and in place, reassemble the inlet valve
assembly and and thread it into the cylinder.
Tighten the
inlet valve housing until the o-ring engages, then continue
to tighten until snug. Once snug, tighten an additional
1/8–1/4 turn.
51. Thread the siphon tube/suction set into the inlet valve
housing and tighten securely.
Make sure to wrap the threads
on the down tube/siphon hose adapter with
PTFE
tape
before
assembly.
52. Replace the return hose into the clamp on the siphon tube.
53. Place the front cover on the gearbox housing and secure
in position using the four front cover screws.
54. Turn on the sprayer by following the procedure in the
“Operation” section of this manual and check for leaks.
NOTE: Repacking kit P/N 0551687 is available. For
best results use all parts supplied in this kit.
NOTE: For low rider units, make sure the hose does
not touch the cart frame. If it does, reposition
the nipple by turning the cylinder until the
hose is clear of the frame and the nipple is
within 45º of the back of the unit.
NOTE: If the nipple on the cylinder does not face the
back of the unit, turn the cylinder
counterclockwise until the nipple faces the
back of the unit. Do not turn the cylinder more
than one full turn.
NOTE: Make sure the raised lip on the bottom of the
lower packing is fully outside the packing
around the piston rod after insertion of the
piston rod.
NOTE: Coat the piston insertion tool (i.e. upper
packing pre-form tool) and the piston rod with
grease before inserting them into the cylinder.
© SprayTECH. All rights reserved.
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