SERVICING
Disassembly
1. Disconnect bypass and inlet plumbing from the regulator.
2. Remove regulator from the pump.
3. Secure lower body of regulator in a vise with adjusting handle
facing upwards.
4. Remove adjusting cap by unthreading from the upper body
in a counterclockwise direction.
5. Remove upper body by unthreading from the lower body.
6. Remove spring retainer, spring set and conical piston.
NOTICE: Exercise extreme caution to avoid contact that could damage
the outside diameter and sharp tip of the conical piston.
7. Remove the lower body from the vise and place it on a flat surface
with the bypass port facing upwards.
8. Using a tool with the same diameter as the conical seat, drive out
the conical seat and piston retainer.
NOTICE: Exercise extreme caution to avoid contact and damage to the
inside diameter of the piston retainer, as well as the outside diameter
and tapered surfaces of the conical seat.
Note: With the regulator completely disassembled, inspect the sealing
area where the conical seat and piston retainer make contact within
the regulator’s lower body for grooves, pitting and wear. If damage is
found, stop the repair and replace the lower body. If damage is more
severe, installation of a new regulator is suggested. If no damage is found,
proceed with the reassembly.
Reassembly
1. Place lower regulator body with bypass port facing downwards
in a vise.
2. Lubricate and install the O-ring onto the outside diameter of the
conical seat. Press the conical seat down into the lower regulator
body with the tapered surface facing upwards.
3. Lubricate and install O-ring onto piston retainer. Press piston retainer
with the larger diameter facing downwards.
4. Place conical piston on a flat surface with the sharp point facing
upwards. Lubricate and install backup ring, then O-ring onto the
outside diameter of the conical piston. Lubricate outside diameter
of conical piston.
5. Press conical piston with the sharp point down into piston retainer.
6. Place the upper body with the large opening facing up.
7. Drop spring retainer into the cap, ensuring spring pilot faces up.
8. Drop in 28 spring washers, alternating direction per exploded view on
the last page.
Note: Use a small rod such as an ink pen to guide the washers into the cap
to ensure the proper orientation is maintained.
9. Invert lower body assembly onto upper body and thread together.
10. Thread adjusting cap into the upper body.
11. Re-install the regulator onto the pump.
12. Reconnect bypass and inlet plumbing to the regulator.
13. Proceed to PRESSURE ADJUSTMENT.
TROUBLESHOOTING
Excessive pressure
fluctuations
• Too little flow for valve specifications
• Air in system, poor connections
• Worn low-pressure seals in the pump
• Worn O-ring in the gun
System will not
build up to
pressure
• Worn nozzle
• Improper nozzle size for system specifications
• Foreign material trapped in seat
Pressure drop • Worn nozzle
• Worn regulator seat or piston
• Air in system, poor connections
• Insufficient flow to pump
• Filter clogged. Check and clean regularly
Pressure spikes
while in bypass
• Minimum bypass of 5% not present
• Excessive pressure adjustment made for worn nozzle
REPLACE NOZZLE. Reset system pressure
Leakage from
regulator vent hole
• Piston retainer scored, or worn O-ring
Service with O-ring kit
Read all CAUTIONS and WARNINGS before commencing service or operation of any high-pressure system
