3
3. Remove the Ball Seat, two Copper Gaskets, Ball, Spring and
Ball Guide (items 6, 7, 8, 9, 18 and 20) from the bore of the
valve body.
4. Pry Plastic Cap (item 3) off of the Spring Washer (item 2).
5. Lightly compress Spring (item 5) by pushing down on the
spring washer and remove the Retaining Rng (item 1).
6. The Release Plunger (item 4) can now be removed from the
Release Guide Assembly (item 19).
3.0 ASSEMBLY
NOTE: Use all new seals provided in repair kit when rebuilding
pump. Lubricate all seals with DS-ES grease.
3.1 Assemble Release Valve Assembly
Refer to Repair Parts Sheet L2533, Figure 8.
1. Install new O-rings (items 13 and 14) and new Back-up
Washers (items 12 and 15) onto the Release Plunger (item 4).
NOTE: Make certain that the back-ups are located to the
outside of the o-rings (closest to both ends of the plunger).
2. Lightly grease o-rings and insert the Release Plunger (item
4) into Release Guide Assembly (item 19).
3. Install new Spring (item 5) over plunger and secure with
spring washer and new Retaining Ring (items 2 and 1). Snap
new Cap (item 3) onto spring washer.
4. Replace O-ring (item 16) located in the bore of the Valve
Block (item 10). Lightly grease o-ring after installation.
5. Place Copper Gasket (item 8) into Valve Block (item 10).
6. Install new Spring and new Ball Guide (items 18 and 20) into
the valve block.
NOTE: New ball seat must be "coined" prior to installation.
Coin seat at 250 psi with an Enerpac 10-ton press.
7. Use small amount of grease to hold new Copper Gasket
(item 7) and new Ball Seat (item 6) to Release Guide (item
19) while installing the assembly into the valve block. (NOTE:
Use DS/ES grease only.) Use grease to hold new Ball (item
9) to the Ball Seat (item 6).
8. Install the completed release guide assembly into the valve
block. Make certain that ball is centered in the seat. Torque
the assembly to 72-78 ft.-lbs [98-105 Nm] (lubricated torque).
3.2 Assemble Release Valve Assembly to Cover
Refer to Repair Parts Sheet L2533, Figure 3 and 8.
NOTE: Make certain that all old gasket material is removed from
the valve block before proceeding.
1. Place Gasket (item 69) onto release valve block. Remove the
paper backing from gasket and position on the valve block
using two of the Screws (item 11) for guides. Attach release
valve block to cover using four Screws (item 11). Torque
screws to 17-19 in.-lbs. [2 Nm] using a cross pattern.
3.3 Install Breather Assembly
Refer to Repair Parts Sheet L2533, Figure 3.
1. Replace O-rings (items 79 and 80) on Breather Assembly
(item 77). Install breather assembly into Cover (item 60).
NOTE: Make certain that the o-rings are in the proper
grooves. Do not reverse items 79 and 80. Also make
certain that the o-rings are lubricated.
3.4 Install Filter
Refer to Repair Parts Sheet L2533, Figure 3.
1. Place new O-ring (item 65) on Swivel Coupler (item 61).
Place new Filter (item 62), cone end first, into swivel coupler.
Attach swivel coupler to cover using Stamped Bracket (item
63) and Screws (item 66), shown in figure 3. Torque screws
to 17-19 in.-lbs [2 Nm].
3.5 Hydraulic Pump Assembly
Refer to Repair Parts Sheet L2533, Figure 4.
1. Install Seal (item 16), Bearing (item 17) and Bearing
Retainer (item 18) into the Hydraulic Cylinder (item 1). Apply
one drop of Loctite 243 to threads of the Bearing Retainer
(item 18) and torque to 34-41 ft.-lbs. [46-55 Nm]. Note the
orientation of the Seal (item 16) in Figure 4.
2. Replace two O-rings (item 3) to the Hydraulic Cylinder (item 1).
3. Slide Mounting Bracket (item 4) onto the Hydraulic Cylinder
(item 1) Secure the Mounting Bracket (item 4) to the Hydraulic
Cylinder (item 1) using the Retaining Ring (item 5) with the
sharp edge away from the Mounting Bracket (item 4).
4. Clamp Hydraulic Cylinder (item 1) into a soft jaw vise.
5. Install Outlet Seat (item 8) and new Copper Washer (item 7)
into the Hydraulic Cylinder (item 1). Apply Loctite 243 on the
threads of the Outlet Seat (item 8) and torque to 34–41 ft. lbs.
[46-55 Nm].
6. Install Outlet Check Ball (item 9), Conical Spring (item 10)
and Ball Guide (item 11) into the Outlet Seat (item 8) Note:
The Conical Spring (item 10) on the outlet check is the
stronger of the two springs that are supplied in the repair kit.
7. Install Pressure Tube (item 13) and new Copper Gasket (item
12) into the Outlet Seal (item 8). Apply loctite 243 to the
threads of the Pressure Tube (item 13) and torque to 34-41
ft.-lbs [34-41 Nm].
8. Replace the two O-rings (item 15) and Backup Rings (item
14) onto the Pressure Tube (item 13). Note the orientation of
the O-rings and Backup Rings on Figure 4.
9. Rotate the clamping of the Hydraulic Cylinder (item 1) in the
soft jaw vise 180 degrees.
10. With a small punch push on the Outlet Check Ball (item 9) to
make sure that the check is installed properly. The ball should
spring back onto the Outlet Check Seat (item 8).
11. Install Ball Guide (item 11), Conical Spring (item 19) and
Intake Check Ball (item 9) into the base of the Outlet Check
(item 8). Note: The Conical Spring (item 10) on the outlet
check is the weaker of the two springs that are supplied in
the repair kit.
12. Install Intake Seat (item 8) and new Copper Washer (item 7)
into the Hydraulic Cylinder (item 1). Apply Loctite 243 on the
threads of the Intake Seat (item 8) and torque to 34–41 ft. lbs.
[46-55 Nm].
13. With a small punch push on the Intake Check Ball (item 9) to
make sure that the check is installed properly. The ball should
spring back onto the Intake Check Seat (item 8).
14. Install Relief Valve (item 6) into the Hydraulic Cylinder (item
1). Apply Loctite 545 to the threads and torque to 10-12 ft-lbs
[14-16 Nm].
15. Do not assembly the Intake Tube Assembly (item 52) into the
Intake Seat (8) at this time. It will be assembled after the
pump assembly is mounted to the cover.