f.
Examine piston (23) seating surfaces and sand clean on flat surface using 240 grit paper. If extreme pitting or
sharp edges, replace piston.
g.
Examine cup (24) for wear, cracking, tearing or separation from the piston. If worn replace and lubricate before
installing on piston (23) NOTE CUP INSTALLATION: Wipe cup inserter with oil. Slip bac-cup ring (when used)
onto piston. Push cup over inserter and square with all surfaces. Faulty cup installation causes premature cup
failure.
h.
Lubricate piston assembly (21) and slip onto piston rod. Replace piston spacer (20) and retainer (19) on rod.
i.
Replace washer (18), thread on nut (17) and torque to 60 in. lbs.
NOTE
Always replace with new STAINLESS STEEL COTTERPIN (16) and turn ends under.
j.
Examine cylinder (14) walls for scoring or etching which causes premature wear of cups and replace if worn.
k.
Lubricate cylinder and replace o-rings (25) if worn or damaged. Carefully slip cylinders over rod ends and
push into inlet manifold in their original position. (front to back).
I.
Position discharge manifold (3) onto pump, install nuts (1) and lockwashers (2) and torque to 217 in. lbs.
4-8.1.3 Servicing Sleeves and Seals.
a.
Remove discharge manifold and piston assemblies as described in 4-8.1.1 and 4-8.1.2.
b.
Remove cylinder bolts (26) and washers (27). Remove inlet manifold (15) containing seals (28).
c.
Grasp sleeves (29) and with a pulling and twisting motion remove the sleeves from the piston rod (30). Note:
Grasp sleeve with pliers only if replacing worn sleeves, as this procedure will mar the sleeves.
d.
Next remove seal retainer (31). Remove and examine o-rings (32) and back-up rings (33) on piston rod (30) for
wear and replace.
e.
Lubricate new o-rings (32) and back-up rings (33) and slip onto piston rod (30). Install the first o-ring in the
groove on the piston rod. Next position back-up ring against the shoulder in front of the first o-ring. Then install
the second o-ring. Exercise caution as you slip the o-ring over the thread end of the piston rod.
f.
While inlet manifold, sleeves and seal retainers are removed, examine crankcase seals for wear.
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