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SERVICING
9. Examine spring retainer (D) and pressure spring
(C) for fatigue or breaks and replace as needed.
10. Place spring retainer (D) into piston retainer (E),
followed by pressure spring (C) after greasing it.
11. Thread brass adjusting cap (A) onto piston retainer
(E) by turning in a clockwise direction.
CERAMIC PLUNGER REPLACEMENT
1. Apply Locktite 242 to exposed threaded end of
plunger retainer (E). See figure 10, page 19.
2. Install ceramic plunger (C) with seal retainer (B)
and washer (D) over each plunger rod shoulder
and thread to torque to specs per chart, See figure
13, page 19.
NOTE: Ceramic plungers can only be installed in one
direction. Counterbore end of ceramic plunger
fits over rod shoulder.
PLUNGER CHAMBER REPLACEMENT
1. Examine high pressure seals (D) or V-Packings
(Not Shown) for frayed edges or uneven wear and
replace as needed. See figure 9, page 18.
2. Examine o-rings (C) for cuts or deterioration and
replace as needed.
3. Examine low pressure seals (A) for wear to the
internal ridges, outer surfaces for broken springs
and replace as needed.
4. Examine seal case (B) for deformation and replace
as needed.
5. Lubricate and install new Hi-Pressure seal (D) by
hand into each manifold chamber with grooved
side down. Depending on the model pump, if
the pump has a male adapter (E), install it with
the notch side down. Lubricate and install new
V-Packing (Not Shown) by hand into manifold
chamber with grooved side down.
6. Lubricate and install o-ring (C) on each seal case
(B). Press small end of seal case (B) into each
manifold chamber.
7. Press new low pressure seal (A) into each seal
case with the spring towards seal case.
MANIFOLD REPLACEMENT
1. Rotate crankshaft by hand so the two outside
plungers are extended equally.
2. Lightly lubricate ceramic plungers, then carefully
slide the manifold head over the ceramic plungers,
supporting it from the underside to avoid damage
to the plungers or seals. Press the manifold head
up to the crankcase until flush. See figure 12, page
19.
3. Thread the hex socket head screws and tighten
in torque in sequence. See figure 11, page 19.
4. Tighten to spec chart. See figure 13, page 19.
CRANKCASE SEAL AND O-RING
REPLACEMENT
1. Remove the four bolts (B) from the bearing cover
(A) on the back of the pump crankcase. Remove
the seal (D) and o-ring (C) from the bearing cover
(A). See figure 14, page 19.
2. Examine the seal (D) and o-ring (C) for cuts and
deterioration and replace as needed.
3. Lubricate and install new seal (D) and o-ring (C)
to the bearing cover (A).
4. Reattach the bearing cover (A) to the crankcase.
See figure 29, page 26 for torque spec.
17
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Troubleshooting
