Cleaning the piston rod

1.Remove the cylinder from the vise.

2.Position the piston rod assembly in the vise and tighten.

CAUTION

The piston rod may be damaged if you are using a vise with steel jaws. Use a vise with aluminum jaws or take precautions to protect the piston rod.

3.Remove the jam nut (21).

4.Remove the retaining nut (20).

5.Remove the outlet valve seat (18), the outlet ball (17), the seal washer (19) and the outlet ball cage (16). Inspect the outlet valve ball and the outlet valve ball seat for damage. If the seat is worn or damaged, it can be flipped to the unused side. If you flip or replace the seat, the ball must be replaced.

6.Remove the lower packings (12, 13), the pressure ring (11), and the wave washer (9).

7.Soak the new leather packings in linseed oil for 5 minutes. Do not over-soak.

8.Clean the disassembled parts in an appropriate solvent.

9.Install the outlet ball cage (16), the outlet ball (17), the outlet valve seat (18) and the seal washer (19), in that order into the piston rod.

10.Apply removable threadlocking compound to the retaining nut threads (20) and screw the retaining nut into the piston rod. Torque the retaining nut to 250 in./lbs.

11.Apply removable threadlocking compound to the jam nut threads (21) and screw the jam nut onto the retaining nut. Torque the jam nut to 200 in./lbs. Remove the piston assembly from the vise.

Replacing the packings

1.Position the wrench flats of the cylinder (8) into the vise and tighten the vise.

2.Insert the wave spring (6), pressure ring (5), upper packings (3, 4) and adapter (2) into the cylinder (8).

NOTE: Make certain to alternate the UHMWPE and leather packings as shown in the illustration.

3.Loosely thread the packing nut (1) into the cylinder.

4.Remove the cylinder from the vise, rotate it and replace it in the vise so that the bottom of the cylinder is facing up.

5.Insert the wave spring (9), the lower pressure ring (11), lower packings (12, 13), the lower ring support (14) and the O-ring (22) into the cylinder.

Inserting the piston rod

1.Insert the piston rod assembly into the cylinder.

2.Insert the O-ring (27) into the inlet valve housing (28).

3.Insert the inlet ball seat (26) and the inlet ball (24) into the inlet valve housing.

4.Insert the stop disk (23) into the inlet ball cage (25) and place them into the inlet valve housing (28).

5.Thread the inlet valve housing assembly onto the bottom of the cylinder assembly. Torque to 40 ft./lbs.

6.Install the large locknut (7) onto the cylinder and turn it until the nut bottoms out on the threaded section of the cylinder.

Attaching the fluid section

1.Remove the assembled fluid section from the vise. Apply anti-seize compound on the upper cylinder threads and thread it into the pump housing. The piston rod (10) will align itself with the slide block.

2.Rotate the fluid section so that the hole in the slide block is aligned with the hole in the piston assembly.

3.Slide the connecting pin through the holes in the slide block and the piston assembly.

4.Replace the cotter pin to hold the connecting pin securely. Refer to the illustration on the previous page.

5.Screw the fluid section into the pump housing as far as it will go. Then unscrew it slightly so that the outlet elbow will align with the fluid hose.

6.Firmly tighten the locknut (7) by turning it clockwise until it is secured tightly against the drive housing.

Repair kits

Item

Part No.

Description

Qty.

1

0279910

Packing kit

 

 

 

(Includes those items marked with an *)

..........1

2

0294689

Inlet valve kit

 

 

 

(Includes those items marked with a +)............

1

Replacing the motor brushes

Brushes should be inspected periodically for wear. If one of the brushes measures less than 1/2", is worn or is chipped, then replace both of the motor brushes. It is recommended that the brushes be replaced when the packings are replaced.

WARNING

ALWAYS follow the PRESSURE RELIEF PROCEDURE found in your manual before starting any troubleshooting, servicing or cleaning.

Removing the motor cord

1.Disconnect the power cord from the electrical supply.

2.Loosen the 4 hex socket head allen screws along the sides of the motor cover and remove the cover.

3.Unscrew and remove the brush caps holding the brushes in place.

4.Pry the brushes out gently with a screwdriver.

5.Install the new brushes, P/N 01694.

6.Install the brush caps. If the old brush caps are damaged, replace them with P/N 01686.

7.Replace the motor cover and hex socket head allen screws.

English

10

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