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of the outlet valve retainer. Torque the outlet valve retainer to
144 in.-lbs.
26. Remove the piston rod from the vise.
27. Clean the cylinder. Inspect the cylinder for damage and
replace if necessary.
28. Place the cylinder upright in a vise by clamping on the wrench
ats.
29. 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.
Install upper packing
with large beveled
edge facing down.
30. Insert the upper packing assembly
into the top of the cylinder with the
large beveled edge facing down.
31. Insert the new adapter ring into the
top of the cylinder with the small,
center protrusion facing down. The
adapter ring should rest on the
upper packing assembly.
32. Apply blue Loctite #242 to the threads of the upper seal
retainer. Thread the upper seal retainer into the cylinder but
do not tighten.
33. Rotate the cylinder in the vise so that the bottom end is facing
up.
34. Pre-form the lower packing using the lower packing sizing
tool (included in the repacking kit).
Install lower packing so
large beveled edge will
be facing up when the
cylinder is upright.
35. 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).
36. 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).
37. Place the piston insertion tool (included in the repacking kit)
over the top of the piston rod.
38. 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.
39. Tighten the upper seal retainer. Torque to 450–480 in./lbs.
NOTE: When repacking the uid 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.
40. Apply blue Loctite to the bottom 3–4 threads on the cylinder.
Turn the jam nut clockwise until it is ush against the top of
the cylinder.
41. Lubricate the rst several threads at the top of the cylinder
with anti-seize compound. Remove the cylinder from vise.
42. 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.
43. Slide the retaining ring down on the slider assembly to cover
the connecting pin.
44. Continue to turn the cylinder clockwise until the jam nut is
ush against the pump housing.
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.
45. Once the nipple is positioned, turn the jam nut clockwise until
it contacts the pump housing.
46. Tighten the jam nut with a wrench to tighten it against the
pump housing. Torque to 960-1000 in./lbs.
47. Attach the high-pressure hose to the tting on the back of the
cylinder and tighten with a wrench. Do not kink the hose.
48. Install new PTFE o-ring onto lower housing. Thread lower
housing into upper housing cylinder. Torque to 680-720 in.-
lbs.
49. Making sure that the new Viton o-ring and new PTFE back-up
ring are lubricated and in place, reassemble the inlet valve
assembly and thread it into the cylinder. Use the new parts
supplied with the packing kit during reassembly. Tighten the
inlet valve housing until the o-ring engages, then continue to
tighten until snug.
50. Using a wrench, hold the cylinder by the wrench ats and
torque the inlet valve housing to 1020–1080 in.-lbs.
51. Place the front cover on the pump housing and secure in
position using the four front cover screws.
52. Turn on the sprayer by following the procedure in the
“Operation” section of this manual and check for leaks.
NOTE: Repacking kit P/N 0555222 is available. For best
results use all parts supplied in this kit.
