User's Manual

Repair
3A0539L 15
Lower Reassembly
1. See FIG. 4. Place the halves of the piston (10)
around the packing (11) and snap them together.
2. Apply high strength (red) Loctite
®
263 or 2760 to
entire length of the piston rod (17) threads. Sealant
must be allowed to cure for a minimum of 12 hours
before use. Screw the rod through the piston and
spacer (44) and into the piston nut (12). Torque the
nut to 95-100 ft-lb (129-135 N•m).
3. With the inlet housing (15) turned upside down,
install the balls (5) and the gaskets (7*).
4. Install the relief valve inlet seat (6) in the left side of
the inlet housing (15), as viewed in F
IG. 4 and FIG.
5. (Text cast into the inlet housing identifies the cor-
rect location for the relief valve seat.) The pin (P) on
the seat must point into the housing. The pin limits
the positioning of the seat, ensuring that the vent is
not blocked by part of the housing. See F
IG. 6.
5. Install the inlet seat without a relief valve (33) in the
right side of the inlet housing (15).
NOTE: The inlet seats (6 and 33) are not reversible; the
chamfered side must face the ball.
6. Place the inlet manifold (18) on the inlet housing
(15). Apply removable (blue) Loctite
®
243 to entire
length of the screw (9) threads. Install the lockwash-
ers (8) and screws (9), and torque to 25-30 ft-lb
(34-40 N•m).
7. Place the inlet manifold (18) in a vise. Place one
o-ring (2*) in each side of the inlet housing (15),
where the tubes (3) sit. Place o-rings (2*) in the
grooves at each end of the tubes. Place a gasket (4)
in both the inlet and outlet housing (15 and 16).
Position the tubes and cylinder (1) in the inlet hous-
ing.
NOTE: It may be necessary to use a rubber mallet to set
the fluid tubes (3) and cylinder (4) in place.
8. Lubricate the inside of the cylinder (4). Slide the pis-
ton assembly into the cylinder. Rotate the piston as
shown in F
IG. 7.
COMPONENT RUPTURE HAZARD
The relief valve seat (6) must be installed at the fluid
inlet, as shown in F
IG. 4 and FIG. 5. The relief valve
reduces the risk of pump overpressurization. The seat
cannot relieve pressure if installed on the other side of
the inlet housing.
F
IG. 6. Inlet Seat with Pressure Relief Valve
TI8407a
7
6
P
ball
spring
pressure relief valve
F
IG. 7. Install Piston in Cylinder
TI8734a