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14. Clean out any debris in the inlet valve housing and
examine the housing and the inlet valve seat. If the seat
is damaged, reverse to the unused side or replace the
seat.
15. Remove the splash guard from the top of the upper seal
retainer.
16. Using a wrench, remove the upper seal retainer.
17. Slide the piston rod out through the bottom of the cylinder.
18. Inspect the piston rod for wear
and replace if necessary.
19. Remove the upper packing
assembly from the top of the
cylinder.
20. Remove the lower support ring
and lower packing assembly
from the bottom of the cylinder.
21. Remove the cylinder from the
vise.
22. Insert the connection pin
through the hole at the top of
the piston rod and clamp each
end of the connecting pin in the
vise. This will hold the piston
rod in position for disassembly.
23. Using a 3/8” hex wrench,
loosen and remove the outlet
valve retainer from the piston
rod.
24. Remove the outlet valve seal,
outlet cage, outlet valve ball,
nylon washer, and outlet valve
seat from the outlet valve
retainer.
25. Clean out any debris and
examine the retainer and outlet
valve seat. If the seat is
damaged, reverse to the unused
side or replace the seat.
26. Clean and inspect the outlet cage and outlet valve ball.
Replace if they are worn or damaged.
27. Reassemble the outlet valve assembly into the piston rod
in the reverse order of how it was disassembled. Torque
the outlet valve retainer to 144 in./lbs.
28. Remove the piston rod from the vise.
29. Clean the cylinder. Inspect the cylinder for damage and
replace if necessary.
30. Place the cylinder upright in a vise by clamping on the
wrench flats.
31. Locate the new upper and lower packing assemblies and
pack the areas between the packing lips with grease.
Lubricate the o-rings on the exterior of the packings with
grease.
32. Insert the upper packing
assembly into the top of the
cylinder with the large beveled
edge facing down.
33. Thread the upper seal retainer
into the cylinder but do not
tighten.
Install upper packing
with large beveled
edge facing down.
Large Beveled Edge
NOTE: Do not clamp the
piston rod directly in
the vise. Damage to
the piston rod will
occur.
NOTE: Be careful not to
scratch, score, or
otherwise damage the
cylinder during
removal of the packing
assemblies.
Piston Rod
Cylinder
Upper
Seal
Retainer
Splash
Guard
Upper
Packing
Assembly
Lower
Packing
Assembly
Outlet Valve
Seat
Nylon Washer
Outlet Cage
Outlet Valve
Ball
Outlet Valve
Seal
Outlet Valve
Retainer
Lower
Support
Ring
34. Rotate the cylinder in the vise so that the bottom end is
facing up.
35. Pre-form the lower packing using the lower packing sizing
tool (included in the repacking kit).
36. Insert the lower packing
assembly partially into the
bottom of the cylinder with the
large beveled edge facing
toward the cylinder (beveled
edge will be facing up when the
cylinder is upright).
37. Push the lower packing
assembly into position using the
lower packing insertion tool (see Fluid Section Assembly
parts list for lower packing insertion tool P/N).
38. Place the piston insertion tool (included in the repacking
kit) over the top of the piston rod.
39. Insert the piston rod into the bottom of the cylinder,
through the lower packing assembly, through the upper
packing assembly, and out through the upper seal
retainer.
40. Tighten the upper seal retainer. Torque to 300–360 in./lbs.
41. Apply blue Loctite to the bottom 3–4 threads on the
cylinder. Turn the jam nut clockwise until it is flush against
the top of the cylinder.
42. Lubricate the first several threads at the top of the cylinder
with anti-seize compound. Remove the cylinder from vise.
43. Place the splash guard over the top of the piston rod and
push down until it is flush against the upper seal retainer.
44. Thread the cylinder into the pump housing, turning
clockwise. When the connecting pin hole on the piston
rod lines up with the hole in the slider assembly, insert the
connecting pin.
45. Slide the retaining ring down on the slider assembly to
cover the connecting pin.
46. Continue to turn the cylinder clockwise until the jam nut is
flush against the pump housing.
47. Once the nipple is positioned, turn the jam nut clockwise
until it contacts the pump housing.
48. Tighten the jam nut with a wrench to tighten it against the
pump housing.
49. Attach the high-pressure hose to the fitting on the back of
the cylinder and tighten with a wrench. Do not kink the
hose.
50. Insert the lower support ring into the bottom of the
cylinder.
51. Making sure that the Viton o-ring and PTFE back-up ring
are lubricated and in place, reassemble the inlet valve
assembly and and thread it into the cylinder. Tighten the
inlet valve housing until the o-ring engages, then continue
to tighten until snug. Once snug, tighten an additional
1/8–1/4 turn.
52. Replace the swivel fitting into the bottom of the fluid
section. Attach the suction set to the swivel fitting.
53. Place the front cover on the pump housing and secure in
position using the four front cover screws.
54. Turn on the sprayer by following the procedure in the
“Operation” section of this manual and check for leaks.
NOTE: Repacking kit P/N 0509510 is available. For
best results use all parts supplied in this kit.
NOTE: If the nipple on the cylinder does not face the
back of the unit, turn the cylinder
counterclockwise until the nipple faces the
back of the unit. Do not turn the cylinder more
than one full turn.
NOTE: When repacking the fluid section, make sure the
raised lip on the bottom of the lower packing
assembly is fully outside the packing around the
piston rod after insertion of the piston rod.
Install lower packing so
large beveled edge will
be facing up when the
cylinder is upright.
Large Beveled Edge
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