WARNING
Always follow the Pressure Relief Procedure War-
ning on page 12 before checking or repairing any
parts.
Displacement Pump Removal and Replacement
Flush the pump if possible. Follow the Pressure Relief
Procedure Warning, on page 12. Be sure to unplug the
power supply cord.
Disconnect the suction (20) and fluid line (1) hoses and
open the pump shield (16). See Fig 6 and Parts Draw-
ing. Remove the socket head screws (32), lockwashers
(311, and flat washer (29) and spacer (63) from the pivot
shaft, and the flat washer (30) and thrust washer (28)
from the crank. Be very careful to hold the pump as you
slide it off the shafts to avoid damaging the needle bear-
ings. See Fig 6.
Repair Kit No. 208940 is available to repair the pump.
Use all of the new parts in the kit, even if the old parts
look good. Old parts wear faster and result in more fre-
quent packing replacement.
Intake Valve Removal and Replacement
Screw the intake valve (51) housing out of the displace-
ment cylinder (54). Remove the ball stop pin (531, guide
(47),
and ball (52). Clean and inspect for wear or
damage. Reassemble, using new parts from the repair
kit. Torque the intake valve housing to 50-150 ft-lb
(68-205
Nmm).
See Fig 7.
NOTE:
You can test the intake valve by filling it with
solvent and seeing if any leaks past the ball.
It should not leak. The valve must be clean
for this test; any dirt will hold the ball off the
seat and let solvent leak past.
Throat Packings, Displacement Rod and Piston
Removal and Replacement
Screw the packing nut (38) out of the displacement
cylinder (54). Carefully pull the displacement rod
assembly (34) and piston housing
(45)
out of the
cylinder. Wrap the rod end with tape to protect the
bearing (36) and clamp securely in a vise. Screw the
piston off the rod using a wrench on the hex of the
piston (if it’s too tight, heat it in boiling water to soften
the locking compound). Remove the ball (461, glands
(41,441 and packings
(42,43).
Slide the throat packings
(61, 62) and glands (39, 40) off the rod. Clean and in-
spect. Install the repair kit parts. Be sure to install the
PTFE and leather packings in the order shown. See
Fig 7 and the Parts Drawing.
Thoroughly clean and degrease the piston housing (45)
and displacement rod (37). Using locking compound,
screw the piston housing onto the displacement rod and
torque to 400-425 in-lb (45-48 N-m). If the packing bulge
makes it hard to insert the piston housing into the
displacement cylinder, loosen the piston housing, insert
it into the cylinder and torque again from the intake end
of the cylinder using a hex socket.
*21
832
DRAIN PLUGA
1
63
Fig 6
35
36
37
LIPS OF V-PACKINGS
3
\
e-61
-4’
4243
44
46
5
54
53
50-160
ft-lb
M8-206
Nmrnl
Fig 7
14 307460
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