HydraMaster Boxxer 318 - Page 38

Machine Maintenance: 4-6
Replace old valves with new valves by placing the assembly in the valve chamber. 5.
Press down rmly on the top of the valve assembly.
Replace valve caps by applying LOCTITE® 243 to valve cap and torque to 33 ft-
6.
lbs.
Removing and Replacing Pump Manifold
Remove the manifold of the pump by taking a 5mm Allen head wrench and removing
1.
the eight head bolts.
With the pump rmly secured, take a medium sized at head screwdriver and apply
2.
pressure to the manifold by prying between the crankcase and manifold. Work
around from all sides of the manifold evenly until it comes off of the pistons. Keep
the manifold properly aligned with the pistons to prevent damage to the seals and
pistons.
When replacing the manifold, turn the crankshaft of pump until the top of the pistons
3.
are closely aligned. Lubricate the pistons and cylinders with grease and evenly press
the manifold toward crankcase until ush.
Seals and V-Packing Maintenance
Remove the manifold as described above. It is possible that the seal and brass
1.
retainer ring assembly will stay on the piston or will remain in the manifold when
removing it.
Carefully remove the brass retainer ring/seal stack. Remove the low-pressure seal
2.
using needle nose pliers. Discard the old seal.
Remove the outer O-ring by taking a small at head screwdriver and working it
3.
under the O-ring. Simply roll off the old O-ring and discard.
The old V-packing stack can be taken apart by hand and discarded.
4.
Seals and V-Packing Reassembly
Generously lubricate parts with grease when reassembling. Examine all brass 1.
components for any damage or water residue build-up. Clean or replace as
needed.
Insert a new low pressure seal by working it in by hand.
2.
Install the new outer O-ring by simply starting on one side and working it into the 3.
groove.
Stack the new V-packing in the correct order and rmly press the assembly into the
4.
manifold.
Install a new low pressure oil seal by laying the seal into the opening and evenly
5.
pressing it into place.
Re-install the manifold onto the pump as previously described.
6.