OIL LEVEL
TOOL KITS
PACKING EXTRACTION KIT - P/N Z09-00028
COMPLETE TOOL KIT - P/N Z09-00021
VALVE SERVICE
1. Remove the plugs holding the valve assemblies.
2. Remove and discard o-rings from the plugs. Clean
plugs with solvent or soap and water. Allow to
dry.
3. Using a needle nose pliers, fingers, or hook
shaped tool, remove the valve assemblies from
the head. Remove and discard the o-rings from
the valve assemblies and/or head. Examine each
valve assembly and discard damaged parts. Refer
to the ”PUMP BREAKDOWN” for part numbers
of any replacement items.
4. Clean any accumulated debris from the valve
cavities and flush with water.
5. Wash the valve assemblies in clean water and
rinse. While still wet, test each valve assembly
by sucking on the valve seat. A properly sealing
valve will allow a good vacuum to be developed
and maintained, while a malfunctioning valve will
not. Good valve assemblies should be set aside
for installation in step 7.
6. Malfunctioning valve assemblies must
be replaced.
7. Lubricate a new o-ring with the pump crankcase
oil and install into valve cavity in the head. Install
a good valve assembly into the cavity as illus-
trated.
8. Lubricate a new o-ring with pump crankcase oil
and place on a plug cleaned in step 2 above.
9. Install a plug into the pump head. Tighten plug
by hand.
10. Torque the plug to the value indicated in the
“TORQUE” section of the pump specifications.
11. Repeat steps 7 through 11 for remaining
valve assemblies.
HEAD REMOVAL
1. Remove the cap screws holding the pump head
to the crankcase. A metric tool is required for
this step. Be careful not to lose the washer on
each cap screw.
2. Remove the head by rotating the crankshaft and
tapping the head away from the crankcase with
a soft mallet. Keep rear surface of the
head parallel to the front surface of the crankcase
to prevent binding on the plungers.
3. Once the head is removed, protect the plungers
from damage.
GENERAL PUMP MAINTENANCE
07-23-03 Z08-00063
ECN-02981 Supersedes 11-14-02 Z08-00063
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6
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