PUMP DISASSEMBLY
NOTE: All threads are right hand. Refer to figure 2 (page 3). Discon- nect air supply and relieve all system pressure prior to servicing. Carefully remove the parts, inspect for damage, nicks or excessive wear and determine if any parts will need replacement.
1.Using a 7/8” wrench, unthread and remove (11) adapter, containing (12 and 13) “O” rings, releasing (14) muffler housing.
2.Using a 7/16” wrench, remove (28) nuts.
3.Remove four (1) bolts, (2) upper cap and (3) gasket.
4.Remove (10) cylinder, containing (4) sleeves and (7) spools.
5.Using (1) bolt, push (7) spools and (4) sleeves out “sleeve” end of (10) cylinder.
6.Remove (16) retaining ring, (17) washer and (19) piston.
7.Remove (22) dowel pin, releasing (20) piston adapter.
8.Remove (3) gasket.
9.Clamp (31) extension tube horizontally in a vise. Unthread and re- move (27) base, (30) gasket, (26) spring and (25) washer. NOTE: Remove (24) rod seal only if replacement is necessary.
10.Pull up on (33) piston rod to reveal (35) cotter pin.
11.Remove (35) cotter pin and (34) connecting pin, releasing (33) pis- ton rod.
12.Using (33) piston rod, push down on (36) connector until it bottoms.
13.Remove (51) retainer ring.
14.Push (50) primer up into (52) primer tube.
15.Lightly wedge a flat blade screwdriver between (50) primer and (52) primer tube, so (50) primer unthreads with (52) primer tube.
16.Insert a 5/16” diameter rod thru the cross holes in (52) primer tube and use the rod to unthread and remove (52) primer tube.
17.Remove (43) spacer, (48) gasket and (49) valve seat from (52) prim- er tube.
18.Remove (44 - 47) foot valve assembly from (41) primer rod.
19.Remove (44) retaining ring, releasing (45) “U” cup. NOTE: Do not remove (46) guide unless replacement is necessary.
20.Remove (42) guide washer.
21.Clamp (37) lower suction tube horizontally in a vise. Unthread and remove (31) extension tube and (32) gasket.
22.Using a 7/32” diameter rod in the cross hole in (36) connector and a 9/16” wrench on the flats of (38) plunger, unthread and remove (36) connector from (38) plunger. NOTE: Do not damage the o.d. of (38) plunger in any way.
23.Using a 5/32” diameter rod in the cross hole of (41) primer rod and a 9/16” wrench on flats of (38) plunger, unthread and remove (41) primer rod, releasing (40) ball and (39) ball stop.
PUMP REASSEMBLY
NOTE: Thoroughly clean and lubricate all seals and bores with Shell Gadus S2 U1000 upon assembly. Replace all soft parts with new ones included in the repair kit. Note: Refer to the illustration (fig- ure 2, page 3) for “U” cup lip seal direction.
1.Assemble (39) ball stop and (40) ball into (38) plunger, securing with (41) primer rod. NOTE: Torque (41) primer rod to 7.9 - 11.3 Nm (70 - 100 in. lbs).
2.Thread (36) connector to (38) plunger, using a 7/32” diameter rod thru the cross hole to tighten. NOTE: Tighten (36) connector to 23.0 - 33.9 Nm (17 - 25 ft lbs).
3.Assemble (46) guide and (45) “U” cup into (47) valve body, securing with (44) retaining ring. NOTE: Assemble chamfered corner of (46) guide into (47) valve body first.
4.Assemble (42) guide washer and (44 - 47) foot valve assembly onto
(41)primer rod.
5.Assemble (43) spacer, (48) gasket and (49) valve seat onto (41) primer rod.
6.Thread (50) primer onto (41) primer rod, securing with (51) retainer ring.
7.Thread (52) primer tube to (37) lower suction tube and tighten. NOTE: Torque (52) primer tube to 88.1 - 101.7 Nm (65 - 75 ft lbs).
8.Assemble (33) piston rod to (36) connector, securing with (34) con- necting pin and (35) cotter pin.
9.Assemble (32) gasket and (31) extension tube to (37) lower suction tube and tighten. NOTE: Torque (31) extension tube to 88.1 - 101.7 Nm (65 - 75 ft lbs).
10.Assemble (23) “O” ring, (24) rod seal, (25) washer, (26) spring and
(30)gasket into (27) base and assemble (27) base to (31) extension tube. Clamp (27) base horizontally in a vise and tighten (31) exten- sion tube. NOTE: Torque (31) extension tube to 88.1 - 101.7 Nm (65 - 75 ft lbs).
11.Push up on (50) primer, exposing (33) piston rod.
12.Assemble (3) gasket to (27) base.
13.Assemble (21) “O” ring to (20) piston adapter and assemble (20) pis- ton adapter to (33) piston rod, securing with (22) dowel pin.
14.Replace (18) “U” cups on (19) piston and assemble (19) piston onto
(20)piston adapter, securing with (17) washer and (16) retaining
ring.
15.Replace (5) “O” rings on (4) sleeves and assemble (4) sleeves into
(10)cylinder. NOTE: Assemble each sleeve into the end of the cylin- der nearest the exhaust hole.
16.Replace (6 and 9) “O” rings and (8) “U” cups on (7) spools and as- semble (7) spools into (10) cylinder from the opposite end as the (4) sleeve went in.
17.Assemble (10) cylinder onto the pump, being careful when sliding over the lips of (18) “U” cups. NOTE: Be sure (3) gasket is seated properly.
18.Replace (3) gasket on (2) upper cap and assemble (2) upper cap to
(10)cylinder.
19.Assemble (1) bolts to pump, securing with (28) nuts. NOTE: Torque
(28)nuts to 9.0 - 10.2 Nm (80 - 90 in. lbs).
20.Replace (12 and 13) “O” rings on (11) adapter.
21.Assemble (15) foam liners to (14) muffler housing.
22.Assemble (14) muffler housing to (10) cylinder, securing with (11) adapter. NOTE: Torque (11) adapter to 7.9 - 9.0 Nm (70 - 80 in. lbs).
TROUBLE SHOOTING
If the pump will not cycle or will not deliver material.
•Be certain to check for
•Check all seals, including track gaskets.
•Check direction of “U” cup lips.
PN
Page 4 of 4 | 559X |
