Page 6-5: High Pressure Pump
Boxxer 421
Reinstall the Ceramic Plungers:
1. Examine the sealing washer on the plunger retainer and replace it if it is
cut or worn. Lubricate the new sealing washer for ease of installation
and to avoid damage.
2. Apply Loctite 242™ to the threads of the plunger retainer and press it into the
ceramic plunger. Thread ‘hand’-tight, then torque the bolt to 4.4 foot pounds.
3. Install the seal retainer with holes to the top and bottom, and forward.
Reinstall High Pressure Manifold
1. Slip the seal retainer over the ceramic plungers with the holes to the top and
bottom and forward.
2. Turn the shaft by hand to line up the plungers so that the end plungers are
parallel.
3. Lightly lubricate the plungers and carefully slide the manifold head onto the
plungers while supporting it from the underside to avoid damaging the
plungers.
4. Reinstall the socket head bolts and torque to 4.4 foot pounds.
Servicing the Crankcase
1. While manifold, plungers, and seal retainers are removed, examine the crank-
case seals for wear.
2. Rotate the crankshaft oil seal externally for drying, cracking or leaking.
3. Consult your HydraMaster distributor if crankcase servicing is necessary.
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