BRUSH REPLACEMENT
American Bosch Brush Replacement
1. The commutator end cap is removed by removing
the hex head cap screws as shown in Figure 3-4
2. While holding the motor in position on the pump,
remove the commutator end cap.
3. Remove the existing brush assemblies and brush
springs.
4. Install the replacement brush assemblies, making
certain that the leads do not contact the
commutator end cap or commutator and that the
chamfered sides of the brushes are away from the
springs. Also install the replacement springs.
5. Tighten the brush holder screws to 35-40 in. lbs.
6. Tighten the motor terminal nut to 50-60 in. lbs.,
and the lock nut to 3-5 in. lbs.
7. Apply a thin film of American Bosch LU3001
grease or equivalent to the armature shaft where
it contacts the end cap bearing.
8. Properly position the gasket and reinstall the
commutator end cap as shown in Figures 3-64
and 3-65.
9. Torque the cap screws and seal the cap screw
heads as shown in Figure 3-40.
Iskra Brush Replacement
See Figure 3-66
VALVE CARTRIDGES “A”, “B” and “C”
IMPORTANT: The valve cartridges can be damaged
beyond repair by bending or denting the tube, the
portion of the cartridge surrounded by the coil.
Therefore, do not grip the cartridge tube with pliers or
clamp it in a vise.
“A” Cartridge
NOTE: Use only a 7/8" or a 1-1/8" hex deep socket to
remove and reinstall the “A” Cartridge.
The “A” Cartridge cannot be disassembled. When
operating normally, the poppet can be pushed in
approximately .030".
Jamming of the poppet due to metal chips or other
contamination can usually be eliminated by immersing
the entire cartridge in clean kerosene and pushing the
poppet in and out with a probe until it moves freely.
Dry with compressed air and reinstall.
In the event jamming cannot be eliminated, replace
the cartridge.
“B” and “C” Cartridges
NOTE: Cartridges without a hex nut must use special
tool No. 21891 to remove and reinstall the “B” and “C”
Cartridges. See Figure 3-67
When jamming of the spool occurs, attempt to
eliminate it using the method described under “A”
Cartridge before disassembling it.
The “B” and “C” Cartridges can be disassembled by
removing the internal retaining ring. When operating
normally, the spool can be pushed in approximately
.070". However, it is generally a better use of one’s
time to replace the cartridge.
In the event jamming or some other malfunction cannot
be eliminated, replace the cartridge since individual
parts for it are not available.
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