17
D10-991-2400B
e. Using petroleum jelly or grease to retain it, install O-ring (65)
and slide housing (30) down over shaft. Be sure holes in
housing and the cylinder housing are properly aligned.
f. Install two assembly studs from Tool Kit, washers and nuts
on threaded studs, but don’t tighten yet. You may want to
insert two or more bolts (4) into unthreaded holes of housing
and cylinder housing to help align parts.
g. Alternately tighten the nuts of assembly studs to evenly draw
housing down to cylinder housing. Be sure O-ring (65) stays
in place.
Also, as you tighten nuts keep checking shaft alignment by
turning shaft (use rotator in Wanner Tool Kit). If shaft begins
to bind and become difficult to turn, back off nuts and realign
shaft. When housing is tight against cylinder housing, you
should be able to turn shaft smoothly.
h. After pump housing and cylinder housing are together,
insert bolt (25) with lock washer (5) (at 4 o’clock position)
through pump housing and into cylinder housing. Repeat
with bolt (29) in 10 o’clock position. Tighten evenly and
then remove assembly studs.
i. Turn shaft again to check its alignment.
5. Replace Shaft Seals
a. Apply thin film of grease on seal protector tool (part of
Wanner Tool Kit). Slide both seals onto tool, with spring side
of seals toward open end of tool.
Apply heavier coat of grease between seals and press
together.
b. Apply coating of Loctite
®
High-Performance Pipe Sealant
with PTFE, or comparable product, to outer surface of both
seals and inside surface of the opening in pump housing
where seals will rest.
c. Apply light film of grease to drive shaft. Slide seal protector
tool (with two seals) over end of shaft.
d. Slide seal inserter tool (from Wanner Tool Kit) over seal
protector tool, and press seals completely into place. Tap
tool with soft mallet to firmly seat seals.
6. Adjust Cam Shaft Endplay
a. Remove three set screws (22) from cylinder casting (24),
and clean them.
b. Insert center bolt (1) into hole in center of cylinder casting.
Turn it in to move bearing adjusting plate (61) and cup tight
against bearing cone.
c. Back out center bolt two full turns, then turn it back in again
until it is tight against adjusting plate (61).
d. Back out the center bolt exactly 1/4 of a turn.
e. With plastic mallet (or regular mallet and wooden board) to
prevent damage to shaft, rap end of shaft 3 or 4 times. This
will provide about 0.006 in. (0.15 mm) endplay in shaft.
f. Apply removable threadlocker to threads of three cleaned
set screws (22).
Screw three set screws (22) into cylinder casting until they
contact bearing adjusting plate (61).
g. Remove center bolt (1).
D/G-10 Service (Hydraulic End)
7. Install Plungers
NOTE: If the plungers (21) have been removed from the
valve plungers (54), do not reuse them. Install new ones
instead.
a. Rotate pump shaft so piston is at top-dead-center
position.
b. Place plunger on exposed screw end of plunger guide tool
(from Wanner Tool Kit). Larger-diameter side of plunger
should face tool.
c. Screw guide (with plunger) into valve plunger (54) until
tight.
d. Hold single bottom handle of guide, and turn double top
handle to force plunger to seat on valve plunger. This is
press-fit. When installed, plunger should be tight against
shoulder of valve plunger.
NOTE: Do not remove the plunger guide until the
diaphragm is installed (see below).
e. Install diaphragm as outlined below, then repeat procedure
for other two plungers and diaphragms.
8. Reinstall Diaphragms
a. With plunger guide tool still screwed into valve plunger (54),
pull valve plunger up until cross-holes in valve plunger are
exposed.
b. Insert diaphragm Allen wrench (from Wanner Tool Kit),
through top hole — to hold plunger (21) away from cylinder
casting. This will also keep valve plunger from turning when
diaphragm is being installed.
c. Place diaphragm (20) onto plunger (21) ridge-side out.
d. Center diaphragm follower (19) on diaphragm.
e. Place O-ring (18) onto follower screw (17).
f. Apply small amount of threadlocker to threads of follower
screw.
g. Insert follower screw (with O-ring) through diaphragm
follower (19) and diaphragm (20), and screw it into valve
plunger (54).
h. Hold plunger holder, and torque follower screw to 18 in.-lbs
(2.0 N-m).
i. Repeat above procedure for plungers and diaphragms of
other two cylinders.
j. Fill reservoir with fresh oil and prime pump, as outlined in
Fluid-End Service Section.
9. Reassemble Pump Head
Reassemble pump head as outlined in Fluid-End Service
Section.
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