Page 6-4 MAXX 450D/470D/Diesel
HydraMaster Corporation10/24/02
Servicing the Low Pressure Seals and High Pressure Seals (cont.)
3. Examine the seal retainer’s o-ring and replace if worn. Lubricate the new o-ring
before installing.
4. Next, press the seal retainers into the manifold until completely seated.
4. Servicing the Plungers (See illustrations above step 3.)
A. Using a hex tool, loosen the plunger retainer about three to four turns.
Push the plunger back to separate it from the retainer and finish
unthreading the plunger retainer by hand.
B. Unthread the plunger retainer with sealing washer.
C. Remove the ceramic plunger, keyhole washer and barrier slinger from
the plunger rod.
D. 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.
5. Reinstall High Pressure Manifold
A. Slip the seal retainer over the ceramic plungers with the holes to the
top and bottom and forward.
B. Turn the shaft by hand to line up the plungers so that the end plungers
are parallel.
C. Lightly lubricate the plungers and carefully slide the manifold head onto
the plungers while supporting it from the underside to avoid damaging
the plungers.
D. Reinstall the socket head bolts and torque to 4.4 foot pounds.
6. Servicing the Crankcase
A. While manifold, plungers, and seal retainers are removed, examine the
crankcase seals for wear.
B. Rotate the crankshaft oil seal externally for drying, cracking or leaking.
C. Consult your HydraMaster distributor if crankcase servicing is
necessary.
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