PLUNGER SERVICE
1. Remove pump head per “HEAD REMOVAL”.
2. Remove any packings and retainers left on the
plungers by pulling them straight off.
3. Examine each plunger, looking for a smooth
surface free of any scoring, cracks, or pitting.
Any defective plungers should be removed per
“PLUNGER REMOVAL”.
4. Discard and replace any defective plungers.
5. Reinstall the plunger per
“PLUNGER INSTALLATION”.
6. Reinstall head per “HEAD INSTALLATION”.
PLUNGER REMOVAL
NOTE: When the plunger screw is removed, it is
important to install new o-ring, anti-extrusion,
and copper washers.
1. Remove the plunger screw is removed, it is
important to install new o-ring, anti-extrusion,
and copper washers.
2. Remove the plunger retaining screw by turning
counterclockwise. Remove and replace copper
washer.
3. Remove and discard o-ring and anti-extrusion
ring from retainer screw.
4. Remove the plunger from the cross head and
examine it for cracks, scoring, or pitting.
5. Remove and discard copper flinger washer, clean
with solvent and allow to dry.
PLUNGER INSTALLATION
1. Install the copper flinger washer onto the cross
head.
2. Slide the plunger onto the crosshead.
3. Lubricate an o-ring with crankcase oil and install
into the groove on the plunger screw. Install the
anti-extrusion ring into the groove next to the o-
ring. Note: The o-ring should be nearest the
screw head and the anti-extrusion ring nearest
the threads.
4. Apply a drop of thread sealant to the threads of
the retainer screw.
5. Thread the plunger retainer screw into the cross
head making sure the copper flat washer is
installed onto the screw.
6. Torque the plunger retainer screw to the value
indicated in the torque section of the pump
specifications.
PACKING SERVICE
1. Remove the head per “PUMP HEAD REMOVAL”.
2. Remove any packings and female adapters left
on the plungers by pulling them straight off.
Insert proper packing extractor onto the
extractor hammer. Insert packing extractor and
tool through the packings and adapters
remaining in the head. Tighten the hammer and
remove the remaining items in the head. Remove
packings and o-rings from adapters. Discard the
o-rings and packings.
3. Clean the packing canities in the head and rinse
with clean water.
4. Clean exposed plungers. Clean male and female
adapters with soap and water and allow to dry.
5. Examine male and female adapters, discard worn
items. Trial fit the female adapters into the head
GENERAL PUMP MAINTENANCE
07-23-03 Z08-00063A
ECN-02981 Supersedes 11-14-02 Z08-00063A
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