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FLUID MANIFOLD SERVICE AND REPAIR
REPACKING FLUID MANIFOLD
IMPORTANT! FOLLOW THE PRESSURE RELIEF PROCEDURE AS STATED ON PAGE 41
IMPORTANT! UNPLUG THE UNIT.
1. Remove the suction set by unthreading the nut (#1) in Diagram F. Then pull the elbow straight down out of the
inlet valve housing (#20) in Diagram A. If you have a Hi Cart, unthread the suction tube #3 on Diagram G.
2. Remove the filter housing (#1), the Filter (#3) and the filter core (#4) in Diagram A.
3. Remove the intake valve housing (#20) in Diagram A.
4. Remove the piston guide (#24) in Diagram A, by inserting a flat head screw driver into the gap between the piston
guide and the intake valve housing. Gently twist the screw driver until the piston guide pops up and is free from
the intake valve housing.
5. Empty the contents of the intake valve housing (lower ball & intake valve seat) Carefully inspect the lower ball
(#17) and the intake valve seat (#18) for any chips or cracks and replace if worn. The seat is two-sided and can be
flipped over if one side is damaged. If you are repacking the unit, you must always replace the lower ball
(#17) and the gaskets (#22) and (#21) in Diagram A.
6. Insert a 15/16" hex key into the piston valve (#15) in Diagram A, and turn counter clockwise to remove. When you
remove the piston valve, there will be an upper ball (#13) and an o-ring (#14) that will come out with it. Carefully
inspect the upper ball and the carbide seat in the top of the piston valve for any cracks or chips and replace if
worn. If you are repacking the unit, always replace the upper ball (#13) and the o-ring (#14) in Diagram A.
7.
To remove the fluid manifold, Diagram A, unthread the transducer #19 in Diagram C from the back of the pump
housing #9, Diagram A using a ¾" open end wrench. Use a small pair of pliers to hold the transducer while loosening
the nut to keep from damaging the transducer. Remove the two hex bolts, #25, Diagram A, using a 5/8" socket
wrench.
8. Remove the Front Cover (#11) in Diagram B.
9. Remove the motor cover (#3) in Diagram B by removing the three screws (#1) and pulling the motor cover straight
back off the motor.
10. Spin the fan (#14) in Diagram B in either direction. The pump housing will lower down away from the crank
housing (#9) in Diagram B. Once the pump housing has cleared the aligning pins on the bottom of the crank
housing, slide the fluid manifold off the connecting rod (#12) in Diagram B.
11. Place the pump housing in a vise and use a 1" open end or adjustable wrench to remove the upper retainer (#6)
in Diagram A.
12. Remove the piston rod (#12) in Diagram A by tapping the top of the piston rod with a rubber mallet.
13. Remove the upper packing (#8) and lower packing (#11) in Diagram A. Inspect both the upper and lower backings
for wear. If you do not intend to replace the packings, do not remove them.
14. When replacing the packings, make sure to apply packing grease to the inside and outside of the packings prior to
insertion. The grease is supplied with the packing kit 600-455.
15. Remove the black packing holder from the upper and lower packings, and apply the grease. The smaller upper
packing (#8) in Diagram A is to be inserted into the top of the pump housing. The packing will only go in direction.
16. Insert the upper guide (#7) into the upper retainer (#6) in Diagram A and thread the upper retainer into the pump
housing. Leave the upper retainer hand-tight until the piston is installed.
17. Insert the lower packing (#11) into the pump housing. It will only go in one direction.
18. Hold the piston rod (#12) upside down and insert the upper ball (#13). Replace the o-ring (#14) on the piston valve
(#15) and thread the piston valve back into the piston rod. Slide the piston rod into the connecting rod (#12) in
Diagram B to hold it steady while you tighten the piston valve firmly.
19. Replace o-rings (#21, 22, 23) in Diagram A. Insert the intake valve seat (#18) and the lower ball (#17) into the
intake valve housing (# 20) all in Diagram A. Insert the piston guide into the intake valve housing pressing firmly
until it snaps into place.
20. Place the piston rod into the intake valve assembly. Use the intake valve assembly to insert the piston rod through
the lower packing. When you thread the intake valve assembly into the pump housing, it will seat the lower
packing correctly and drive the piston through the upper packing. Use a number 12 adjustable wrench to tighten.
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