Lincoln SKF FlowMaster II A Series Instruction Manual

User and maintenance instructions
Models 85731, 5 U.S. gallons, 85732, 60 lbs (27 kg), 85733, 120 lbs (54 kg), 85734, 400 lbs
(181 kg), 85138, 400 lbs (181 kg), 85144 (CAT branded)
FlowMaster II rotary driven
hydraulic pump series “A”
Date of issue February 2023
Form number 404554
Version 6

Contents
Declaration of Incorporation* . . . . . . . 3
U.K. Declaration of Incorporation* . . . 4
Safety* . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Explanation of signal words for safety* . 5
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview . . . . . . . . . . . . . . . . . . . . . . . . 6
Appropriate use. . . . . . . . . . . . . . . . . . . 6
Description. . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . 7
Damaged pumps . . . . . . . . . . . . . . . . . . 7
Pump specifications . . . . . . . . . . . . . . 7
Grease output vs. hydraulic input. . . . 8
Hydraulic schematic . . . . . . . . . . . . . . 8
Pump dimensions. . . . . . . . . . . . . . . . 9
Installation and operation . . . . . . . . . . 10
Install pump. . . . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . 11
Set pump manifold pressure and flow
controls . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure control valve adjustment . . . . 12
Flow control valve adjustment . . . . . . . . 12
Crankcase oil service interval . . . . . . . . . 12
Maintenance and repair . . . . . . . . . . . . 13
Disassembly. . . . . . . . . . . . . . . . . . . . . . 13
Crank rod and eccentric . . . . . . . . . . . . . 15
Reciprocating tube . . . . . . . . . . . . . . . . . 15
Crank rod . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 17
Crank rod and eccentric . . . . . . . . . . . . . 17
Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Troubleshooting . . . . . . . . . . . . . . . . . 21
Parts list . . . . . . . . . . . . . . . . . . . . . . . 25
Non-common repair parts . . . . . . . . . 25
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 28
2

Declaration of Incorporation* DOCUMENT NUMBER
404554.DoI
Manufacturer name/address:
Lincoln Industrial Corporation
5148 N. Hanley Road
St. Louis, MO 63134 U.S.A.
TEL: [phone] FAX: [phone]
Authorized to compile the technical file:
SKF Lubrication Systems Germany GmbH
Heinrich-Hertz-Straße 2-8
69190 Walldorf, Germany
TEL: [phone]
EMAIL: [e-mail] WEBSITE: www.skf.com
This Declaration of Incorporation is issued
under sole responsibility of the
manufacturer. Lincoln Industrial Corporation
hereby declares that the partly completed
machinery stated below:
Name: FlowMaster II
Model number(s):
Model number(s):
Description:
Year of CE: 2022
in its intended use, is in conformity with the
relevant union harmonization legislation:
Machinery Directive 2006/42/EC (article 13
Partly Completed Machinery)
and conforms to the following harmonized
standards:
EN ISO 4413: 2010
Hydraulic fluid power - general rules and
safety requirements for systems and their
components
EN ISO 12100: 2010
Safety of machinery. General principles for
design. Risk assessment and risk
reduction
EN ISO 809:1998+A1:2009
Pumps and pump unites for liquids - com-
mon safety requirements
EN 12162: 2009
Liquid pumps. Safety requirements. Pro-
ceedure for hydrostatic testing
EN 349: 1993
Safety of machinery. Minimum gaps to
avoid crushing of parts of the human body
I, the undersigned of Lincoln Industrial Corporation, do hereby declare that the equipment specified above, in its intended use, conforms to
the requirements of the above EC Directive(s).
___________________________________
Robert Collins
Technical Compliance Manager
St. Louis, MO, U.S.A.
The following EHSR (Essential Health and
Safety Requirements) have been applied:
1.1.2a – 1.1.2b – 1.1.2c– 1.1.3 – 1.1.5 – 1.2.5
– 1.3.2 – 1.3.2 – 1.3.3 – 1.3.4 – 1.3.6 – 1.3.7
– 1.3.8 – 1.5.3 – 1.5.4 – 1.7 – 1.7.1 – 1.7.1.1
– 1.7.3 – 1.7.4
The manufacturer maintains a technical file
summary sheet containing test reports and
product documentation:
Technical file summary sheet number:
The partly completed machinery shown
above should not be put into service until the
final machinery into which it is to be
incorporated has been declared in conformity
with the provisions of the directive, where
appropriate.
RA404554
85144 (602-4050 CAT)
85731, 85732, 85733,
85734 and 85138
Rotary driven hydraulic
pumps (series “A”)
2022/06/14 *Indicates change
3

U.K. Declaration of Incorporation* DOCUMENT NUMBER
UK404554CA
Manufacturer name/address:
Lincoln Industrial Corporation
5148 N. Hanley Road
St. Louis, MO 63134 U.S.A.
TEL: [phone] FAX: [phone]
Authorized to compile the technical file:
SKF (U.K.) Limited
2 Canada Close
Banbury, Oxfordshire, OX16 2RT, GBR
EMAIL: [e-mail] WEBSITE: www.skf.com
This U.K. Declaration of Incorporation is
issued under sole responsibility of the
manufacturer. Lincoln Industrial Corporation
hereby declares that the partly completed
machinery stated below:
Name: FlowMaster II
Model number(s):
Model number(s):
Description:
Year of CE: 2022
in its intended use, is in conformity with the
relevant union harmonization legislation:
Supply of Machinery (Safety) Regulations
2008 (2008 No. 1597)
along with the following Directive(s) that
were also applied with the above legislation:
EN ISO 4413: 2010
Hydraulic fluid power - general rules and
safety requirements for systems and their
components
EN ISO 12100: 2010
Safety of machinery. General principles for
design. Risk assessment and risk
reduction
EN ISO 809:1998+A1:2009
Pumps and pump unites for liquids - com-
mon safety requirements
EN 12162: 2009
Liquid pumps. Safety requirements. Pro-
ceedure for hydrostatic testing
EN 349: 1993
Safety of machinery. Minimum gaps to
avoid crushing of parts of the human body
I, the undersigned of Lincoln Industrial Corporation, hereby declare that the equipment specified above, in its intended use, conforms with the
Essential Health and Safety Requirements of U.K. legislation Supply of Machinery (Safety) Regulations 2008 No. 1597 Annex I, Declaration of
Incorporation by the time of placing it on the market.
___________________________________
Robert Collins
Technical Compliance Manager
St. Louis, MO, U.S.A.
The following EHSR (Essential Health and
Safety Requirements) have been applied:
1.1.2a – 1.1.2b – 1.1.2c– 1.1.3 – 1.1.5 – 1.2.5
– 1.3.2 – 1.3.2 – 1.3.3 – 1.3.4 – 1.3.6 – 1.3.7
– 1.3.8 – 1.5.3 – 1.5.4 – 1.7 – 1.7.1 – 1.7.1.1
– 1.7.3 – 1.7.4
The manufacturer maintains a technical file
summary sheet containing test reports and
product documentation:
Technical file summary sheet number:
The partly completed machinery shown
above should not be put into service until the
final machinery into which it is to be
incorporated has been declared in conformity
with the provisions of the directive, where
appropriate.
RA402139
85144 (602-4050 CAT)
85731, 85732, 85733,
85734 and 85138
Rotary driven hydraulic
pumps (series “A”)
2022/03/10 *Indicates change
4

Safety*
The assembly must be installed, maintained
and repaired exclusively by persons familiar
with the instructions.
Always disconnect power source
(electricity, air or hydraulic) from the
equipment when it is not being used.
This equipment generates high pressure.
Extreme caution should be used when
operating this equipment as material leaks
from loose or ruptured components can
inject fluid through the skin and into the
body. If any fluid appears to penetrate the
skin, seek attention from a doctor
immediately. Do not treat injury as a simple
cut. Tell attending doctor exactly what type of
fluid was injected.
Any other use not in accordance with
instructions will result in loss of claim for
warranty or liability.
• Do not misuse, over-pressurize, modify
parts, use incompatible chemicals, fluids,
or use worn and/or damaged parts.
• Do not exceed the stated maximum
working pressure of the equipment or of
the lowest rated component in your
system.
• Always read and follow the manufacturer’s
recommendations regarding fluid
compatibility, and the use of protective
clothing and equipment.
• Failure to comply may result in personal
injury and/or damage to equipment.
CAUTION
Do not operate equipment without
wearing personal protective gear.
Wear eye protection. Protective
equipment such as dust mask, non-skid
safety shoes, hard hat, or hearing pro-
tection used for appropriate conditions
will reduce personal injuries.
Failure to comply may result in light
personal injury.
WARNING
Do not allow any body part
to be trapped by equipment.
Body parts can be crushed
by subassemblies during
operation.
Failure to comply may result in death
or serious physical injury.
WARNING
Do not allow fluid to leak
onto floor when operating
equipment. If spill occurs,
clean any fluid on floor before continuing
operation.
Failure to comply may result in death
or serious personal injury.
WARNING
Do not use this equipment to supply,
transport, or store hazardous
substances and mixtures in accordance
with annex I part 2-5 of the CLP
regulation (EG 1272/2008) or HCS 29
CFR 1910.1200 marked with GHS01,
GHS06 and GHS08 hazard pictograms
shown:
Explanation of signal words
for safety*
NOTE
Emphasizes useful hints and
recommendations as well as
information to prevent property damage
and ensure efficient trouble-free
operation.
CAUTION
Indicates a dangerous situation that can
lead to light personal injury if
precautionary measures are ignored.
WARNING
Indicates a dangerous situation that
could lead to death or serious injury if
precautionary measures are ignored.
DANGER
Indicates a dangerous situation that will
lead to death or serious injury if
precautionary measures are ignored.
WARNING
Do not operate equipment
without reading and fully
understanding safety
warnings and instructions.
Failure to follow warnings and
instructions may result in serious injury.
*Indicates change
5

Overview
This service page details the procedure that
must be followed while installing, operating
and repairing the FlowMaster II rotary driven
hydraulic pump.
All required parts, tools, and equipment
needed to complete the operation of the
FlowMaster II rotary driven hydraulic pump
are defined and listed within this manual.
Review of the parts list and nomenclature is
recommended before starting disassembly
or operation.
Appropriate use
All models are designed to pump and
dispense lubricants using hydraulic power.
Specifications are shown in Table 1, page 7
for pump.
Do not exceed maximum specification
ratings.
Do not exceed 3 000 psi (206 bar)
maximum supply inlet hydraulic pressure.
Exceeding rated pressure may result in
personal injury or damage to system
components.
Any other use not in accordance with
instructions will result in loss of claims for
warranty and liability.
Description
FlowMaster II rotary driven hydraulic pump
is a fully hydraulically operated adjustable
grease pump.
Grease output is proportional to hydraulic
input flow. Pump is primarily designed for
centralized lubrication systems such as
single line parallel, single line progressive
and two line systems. Integrated pump
control manifold is incorporated with input
flow and pressure.
Fig. 1, page 8 details grease output in
proportion to the hydraulic input that is
affected by temperature.
The models 85731 (5 gallon (18 liter)),
85732 (60 gallon (227 liter)), 85733 (120 lb
(181 kg)), 85734 (400 lb (181 kg)), 85138
(400 lb (181 kg)), and 85144 (CAT branded)
are similar, with main difference between
length of housing tube.
24 V solenoid valve is also
incorporated as a method to turn pump
on and off.
Pump is driven by rotary motion of
hydraulic motor. Rotary motion is converted
to reciprocating motion through eccentric
crank mechanism. Reciprocating action
causes pump cylinder to move up and down.
Unit is a positive displacement double-acting
pump, as grease output occurs during both
up and down stroke.
During down stroke, pump cylinder is
extended into grease. Through combination
Usage
of shovel action and vacuum generated in
pump cylinder chamber, grease is forced into
pump cylinder. Simultaneously, grease is
discharged through outlet of pump. Volume
of grease during intake is twice the amount
of grease output during one cycle. During
upstroke, inlet check closes, and one half of
grease taken in during previous stroke is
transferred through outlet check and
discharged to outlet port.
Fig. 2, page 8 is the hydraulic schematic
showing key sub-assemblies of the pump
with actual location of those items shown
in Fig. 3, page 9.
6

Inspection
If over pressurizing of equipment is believed
to have occurred, contact nearest factory
authorized warranty and service center for
inspection of pump. Specialized equipment
and knowledge is required for repair of pump.
Annual inspection by nearest factory
authorized warranty and service center is
recommended.
Damaged pumps
Do not use any pump that appears to be
damaged, badly worn or operates
abnormally.
Remove pump from service and contact
nearest factory authorized warranty and
service center for repairs. Listing of autho-
rized warranty and service centers is avail-
able upon request.
Table 1
Pump specifications
Hydraulic inlet flow 2 U.S. gpm (7,6 liters/min)
Operating temperature –40 to 150 °F (–40 to 65 °C)
Operating working hydraulic pressure 300 psi (21 bar)
Solenoid voltage, for the on/off solenoid 24 V
Hydraulic inlet port, in SAE 4
Tank return port, in SAE 6
Supply inlet hydraulic pressure Maximum 3 000 psi (206 bar)
Pump outlets, in 1/4in NPTF
Maximum hydraulic fluid temperature 250 °F (121 °C)
Pump ratio with manifold 10:1
7

5 (81)
1.0
(3.7)
1.5
(5.6)
2.0
(7.5)
2.5
(9.4)
3.0
(11.3)
3.5
(13.2)
4.0
(15.1)
4.5
(17.0)
5.0
(18.9)
10 (163)
15 (245)
20 (327)
25 (409)
30 (491)
35 (573)
40 (655)
80 °F (27 °C)
20 °F (–2 °C)
0 °F (–18 °C)
–20 °F (–29 °C)
T
P
1
10
6
5
7
9
8
2
3
4
Fig. 1
Grease output vs. hydraulic input
Hydraulic input
gpm (liter/min)
Grease output
in3/min (cm3/min)
Fig. 2
Hydraulic schematic
Item Description
1Hydraulic fluid inlet port SAE 4 ORB
2 Hydraulic fluid return to tank SAE 6 ORB
3 Hydraulic motor
4 Lube outlets 1/4in NPTF
5Flow control valve
6 Pressure gauge
7 Hydraulic fluid to vent valve
8 Orifice 0.013 in (0.33 mm) diameter
9 Pressure reducing valve
10 Solenoid valve
8

2.25 in
(57 mm)
2.25 in
(57 mm)
3.90 in
(99 mm)
(4×) ∅ 0.28
in (7 mm)
(4×) 1/4-20
9.09 in
(231 mm)
∅ 1.25 in
(32 mm)
A
B
9.37 in
(238 mm)
11.53 in
(293 mm)
2.72 in
(69 mm)
Fig. 3
Pump dimensions
Model Dimension ADimension B
85731 25.08 in (637 mm)13.74 in (349 mm)
85732 30.39 in (722 mm)19.05 in (484 mm)
85733 38.90 in (988 mm)27.56 in (700 mm)
85734 45.40 in (1 153 mm)34.06 in (865 mm)
85138 45.40 in (1 153 mm)34.06 in (865 mm)
85144 25.08 in (637 mm)13.74 in (349 mm)
9

A
69
66
37
70
67, 68
B
C
64
Fig. 4
Item Description
AHydraulic fluid inlet port SAE 4 ORB
B Hydraulic fluid return to tank SAE 6 ORB
C Gasket
37 Pump housing
64 Pressure gauge
66 Manifold
67 Solenoid valve
68 Solenoid coil (24 V )
69 Flow regulator
70 Pressure reducing valve
72 Hydraulic motor
Installation and operation
Install pump
Pump was tested in lightweight oil that was
left in to protect pump from corrosion. Flush
pump before connecting it to system to
prevent contamination of grease with
residual oil.
Pump has flow and pressure controls
integrated into manifold (66). Normally
closed on/off solenoid valve (67 and 68) is
also integrated into manifold and will start or
stop pump operation.
NOTE
Refer to fig. 3, page 9 for hole pattern
and dimensions if it is necessary to drill
mounting holes into reservoir cover.
WARNING
Do not operate pump without shut-off
valve in material supply line.
Failure to comply may lead to death or
serious injury.
1 Mount pump securely on drum cover to
prevent movement or vibration during
operation (→fig. 4).
2 Attach hydraulic supply line to inlet (A) and
return line to tank ports.
3 Connect material supply line to pump
outlet.
4 Plug unused outlet on opposite side of
pump.
5 Install high pressure shut-off valve in
material supply line (required).
6 Connect 24 V power supply to
solenoid coil (74), using supplied plug.
10

A
67, 68
69
66
37
70
B
64
Operation
NOTE
Do not change settings for pump until
after start up procedure. All pumps are
factory set at 320 psi (22 bar) working
inlet hydraulic pressure with flow rate of
2.5 gallons/min (9.5 liters/min).
Failure to comply may result in dam-
age to equipment.
NOTE
Do not exceed maximum operating
temperature of hydraulic fluid 250 °F
(121 °C).
Never allow pump to run dry of lubri-
cant. Dry pump quickly speeds up, cre-
ating friction heat that can damage
seals. Monitor supply lubricant level and
refill when necessary.
Failure to comply may result in dam-
age to equipment.
NOTE
Refer to Set pump manifold pressure
and flow controls (page 12) for
instructions to adjust pressure and flow.
See fig. 5 for location of operating
valves.
Do not exceed pump operating pres-
sure of 400 psi (27 bar). Always use the
lowest pump output pressure and
hydraulic fluid flow to obtain desired
results. This will reduce pump wear.
Pressure of 320 psi (22 bar) is
recommended.
Failure to comply may result in dam-
age to equipment.
WARNING
Do not exceed 400 psi (27 bar) working
hydraulic pressure. Use high pressure
components to reduce risk of serious
injury including fluid injection and
splashing in eyes or on skin.
Do not connect accessories to pump
outlet that are not approved for up to
5 000 psi (344 bar) minimum hydraulic
operating pressure. Do not connect
accessories that operate below
3 000 psi (206 bar) minimum
working pressure.
Failure to comply may result in per-
sonal injury.
1 Shut off material supply line valve.
2 Turn on hydraulic pressure.
3 Energize solenoid on/off valve (67)
(→fig. 5).
4 Prime pump by slowly opening shut-off
lubricant supply line valve.
5 Make sure all air has been expelled from
pump and even lubricant flow is achieved.
6 Adjust pump pressure and flow to desired
application requirements.
Fig. 5
Item Description
AHydraulic fluid inlet port SAE 4 ORB
B Hydraulic fluid return to tank SAE 6 ORB
37 Pump housing
64 Pressure gauge
66 Manifold
67 Solenoid valve
68 Solenoid coil (24 V )
69 Flow regulator
70 Pressure reducing valve
72 Hydraulic motor
11

NOTE
Pressure must be adjusted to make sure
desired flow setting is achieved.
Fig. 5 (page 11)depicts location of
valves.
NOTE
Do not exceed 400 psi (27 bar). Pressure
of 320 psi (22 bar) is recommended.
Damage to equipment may occur.
NOTE
Adjustment screw will unscrew until it
reaches stop. It will not come off. This is
the minimum pressure setting, about
100 psi (6 bar).
NOTE
Flow control valve can be turned in until
valve is completely closed and out to
adjust pump speed.
Recommended flow control valve set-
ting is 1/4* turn counter clockwise.
Flow control valve
adjustment
6 Loosen hex head cap and remove from
flow regulator (69) (→fig. 5).
7 Adjust flow by turning hex head screw
clockwise to reduce flow and coun-
ter-clockwise to increase it.
8 Once flow rate is at desired level, install
and tighten hex head cap on flow
regulator (69).
Set pump manifold
pressure and flow
controls
Pressure control valve
adjustment
1 With hydraulic pressure applied, stop
pump by turning flow regulator (69) clock-
wise until completely closed.
2 Remove hex head cap from pressure
reducing valve (70).
3 Turn hex head adjustment screw coun-
ter-clockwise until it stops.
4 With pump (37) stalled against pressure,
turn pressure reducing valve (70) hex
head clockwise until desired pressure is
reached on manifold pressure gauge (64).
5 Install and tighten pressure reducing
valve (70) hex head by turning lock nut
clockwise.
Crankcase oil service interval
• Check oil level after every 750 hours of
machine operation, or monthly.
• Change oil after every 2 000 hours of
machine operation or every year.
• Use SAE 10W30 motor oil in all units used
in an ambient temperature between
-40 to 150 °F (-40 to 65 °C). For ambient
temperatures between 50 to 70 °F
(10 to 21 °C) , use low temperature oil.
• Oil level should be at indicating dot on dip-
stick (middle of crankshaft).
• Use 10W30 motor oil 15 oz (0.44 l).
* Indicates change.
12

Maintenance and repair
Disassembly
Pump
1 Place pump into vise.
2
Remove dipstick (31) (→fig. 6, page 14).
3 Drain crankcase oil.
4 Remove housing cover screws (33).
5 Remove housing cover (35) and
gasket (36).
6 Remove hydraulic motor mounting
screws (74) and lock washers (73).
7 Remove hydraulic motor (72).
8 Remove manifold mounting screws (65)
and manifold assembly (66).
9 Remove pressure reducing valve (70).
10 Remove flow regulator (69).
11 Remove solenoid valve cartridge (67).
12 Remove outlet pin nuts (55) from both
sides of pump housing (37).
13 Remove o-rings (54 and 53) and
back-up washer (52) from outlet pin
nuts (55).
23 Remove back-up washer (58) from tube
housing (60).
24 Remove o-ring (59) from tube
housing (60).
25 Using a rubber mallet and piece of brass
or other suitable piece of soft metal, tap
on crank rod (7) inside housing (37).
26 Pull eccentric (5) and crank rod (7) out of
top of pump housing (37).
NOTE
Slight force may be necessary to remove
eccentric (5) and crank rod (7) from
housing (37). Tap on crank rod (7) until
eccentric (5) is above pump housing (37)
and can be pulled from pump
housing (37).
14 Loosen screws (44) holding shaft
cover (46) on pump housing (37)
(→fig. 8, page 14).
15 Remove retaining ring (48) from pump
shaft (40).
16 Remove pump shaft (40) by pushing
pump shaft on retaining ring (48) side.
17 Remove retaining ring (63) from housing
tube (60) (→fig. 7, page 14).
18 Remove shovel plug (62) from housing
tube (60).
19 Remove spiral retaining ring (61).
20 Loosen and remove tube housing (60).
21 Remove bronze bearing (56) from tube
housing (60).
22 Remove o-ring (57) from tube
housing (60).
13

31
73, 74
33, 34
67
69
36
66
37
70
72
55
64
65
35
43
39
40
41
42
38
37
5 7
31
32
35
36
44
45
46
47
48
49
50
51
52
53
54
55
60
33
34
56
57
58
59
60
61
62
63
Fig. 6 Fig. 8
Fig. 7
14

NOTE
Wrist pin bushings (12) often stick
in wrist pin anchor (13). It may be
necessary to use 5/16 – 24 bolt from
kit 276275 to remove wrist pin
bushings (12).
1 Remove pivot screws (11) from crank
rod (7) (→fig. 9, page 16).
2 Press out wrist pin bushing (12).
3 Loosen and remove wrist pin anchor (13)
from reciprocating tube (25).
4 Pull cup seal (16) out of wrist pin
anchor (13).
5 Remove steel back-up ring (17).
6 Place plunger link rod (20) in vise.
7 Loosen plunger link rod (20) and remove
from outlet pin (8).
8 Remove plunger link rod (20).
9 Remove retainer clip (19) from plunger
link rod (20).
10 Remove o-ring (18) from plunger link
rod (20).
11 Remove back-up washer (15) from
plunger link rod (20).
12
Remove o-ring (14) from plunger tube (25).
13 With crank rod in vise and using special
tool (T1) provided in tool kit, 276275
remove plunger link rod (20).
14 Place end of plunger link rod (20) into
hole of special tool (T1).
15 Align outlet hole of plunger link rod (20)
with hole in special tool (T1).
16 Insert pin included in tool kit 276275
through tool and into plunger link
rod (20) outlet hole.
17 Turn tool counter clockwise to loosen
lower bushing and plunger (24) from
plunger link rod (20).
18 Remove plunger (24).
19 Remove check rod from (22) lower bush-
ing and plunger (24).
20 Remove ball (23) from lower bushing
and plunger (24).
21 Remove spring (21) from link rod (20).
Crank rod and eccentric Reciprocating tube
1 Loosen check seat housing (30) with
3/8in (9 mm)hex head wrench (→fig. 9,
page 16).
2 Remove check seat housing (30) from
reciprocating tube (25).
3 Remove ball cage (28), check ball (29)
and o-ring seal (27) from check seat
housing (30).
4 Remove lower bushing (24) from
reciprocating tube (25).
5 Remove lower cup seal (26) from
reciprocating tube (25).
Crank rod
1 Loosen and remove two flat head
screws (1) from eccentric (5)
(→fig. 9, page 16).
2 Remove counterbalance weights (2).
3 Remove outer (3) and inner (4) retaining
ring from both sides of crank rod (7).
4 Place crank rod (7) on supplied
2 1/2in (62 mm) diameter steel pipe.
5 Drive crank eccentric (5) out of ball
bearing (6).
6 Drive ball bearing (6) out of crank rod (7).
15

12
43
1112
1
2
3
4
5
6
7
8
9
10
11 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
T1
Fig. 9
16

12
43
1112
1
2
3
4
5
6
7
8
9
10
11 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
T1
Assembly
Crank rod and eccentric
1 Place crank rod (7) on 2 1/2in (62 mm)
diameter steel pipe, provided in tool kit
276275 (→fig. 10).
2 Install ball bearing assembly (6) into
crank rod (7).
3 Place eccentric (5) in ball bearing (6).
4 Place one end of inner retaining ring (4)
on top of eccentric (5).
5 Squeeze other end of retaining ring (4)
toward center and slide retaining ring (4)
into place.
6 Place one end of outer retaining ring (3)
on top of inner retaining ring (4).
7 Squeeze other end of retaining ring (3)
toward center and slide retaining ring (3)
into place.
8 Align holes of counter-balance
weights (2) with threaded holes of
eccentric (5) and place on eccentric (5).
9 Insert flat head screws (1) into counter-
balance weight (2) and torque flat head
screws (1) to a torque of
100 to 110 in-lbf (11.3 to 12.4 Nm).
Fig. 10
17

7
12
13
11
56
57
58
59
60
61
62
63
Pump
1 Install ball (23) into lower bushing and
plunger (24) (→Fig. 10, page 17).
2 Insert check rod (22) into pump
plunger (23).
3 Place spring (21) onto check rod (22).
4 Thread plunger link rod (20) into pump
plunger (24).
5 Insert lower bushing pump plunger (24)
into tool (T1).
6 Align hole in lower bushing pump
plunger (24) with hole in tool (T1).
7 Insert pin provided in tool kit 276275 into
hole of tool (T1) and into lower bushing
pump plunger (24).
8 Torque lower bushing pump plunger (24)
to 110 to 125 in-lbf (12.4 to 14.1 Nm).
9 Install steel back-up ring (17) onto
threads of upper bushing and plunger
end (10).
10 Slide o-ring (18) onto upper bushing and
plunger end (10).
11 Install retaining clip (19) on upper bush-
ing and plunger end (10).
12 Install o-ring (9) on upper bushing and
plunger end (10).
13 Place outlet pin (8) into a vise.
14 Apply thread locker to the threads of the
upper bushing and plunger end (10).
15 Thread the upper bushing and plunger
end (10) into the outlet pin (8).
16
Torque to 110 to 125 in-lbf (12.4 to 14.1 Nm).
17 Install the back-up washer (15) in the
wrist pin anchor (13).
18 Place a new cup seal (16) inside the wrist
pin anchor (13).
19 Clean threads of wrist pin anchor (13).
20 Install o-ring (14) on wrist pin
anchor (13).
21 Insert upper bushing and plunger
end (10) into wrist pin anchor (13) and
tighten.
22 Place wrist pin anchor (13) in a vise.
23 Tighten wrist pin anchor (13) to torque of
20 to 25 ft-lbf (27 to 34 Nm).
24 With wrist pin anchor (13) still in vise,
align crankrod/eccentric assem-
bly (7) holes with wrist pin anchor (13)
(→fig. 11).
25 Install wrist pin bushings (12) through
crank rod (7) and into wrist pin
anchor (13).
26 Apply thread locker to threads of wrist
pin bushing screws (11).
27 Insert and thread wrist pin bushing
screws (11) into crankrod (7).
28 Tighten bushing screws (11) to torque of
110 to 125 in-lbf (12.4 to 14.1 Nm).
Fig. 11
32 Install steel check cage (28) into recipro-
cating tube (25).
33 Install ball (29) into steel check cage (28).
34 Apply thread locker to threads of check
seat housing (30).
35 Thread check seat housing (30) into
reciprocating tube (25) and tighten using
3/8in (9 mm) hex key.
36 Torque to 20 to 25 ft-lbf (27 to 33 Nm).
37 Remove crank rod (7) from vise.
38 Insert o-ring (59) into housing tube (60)
(→Fig. 12, page 18).
39 Place back-up washer (58) into housing
tube (60).
40 Insert o-ring (57) into housing tube (60).
41 Insert bronze bearing (56) into housing
tube (60).
NOTE
For ease of installation of lower cup, use
small piece of tubing to slide lower up
into reciprocating tube and over pump
plunger.
Fig. 12
29 Install cup seal (26) with slotted side
toward center of reciprocating tube (25)
(→fig. 10, page 17).
30 Place new o-ring (27) on lower bushing
and plunger (24).
31 Slide lower bushing and plunger (24)
into reciprocating tube (25) with
o-ring (27) near bottom of reciprocating
tube (25).
18

43
39
40
41
42
38
37
5 7
31
32
35
36
44
45
46
47
48
49
50
51
52
53
54
55
60
33
34
5
43 Align crank rod (7) with shaft (40)
mounting hole.
44 While aligning key (39) on shaft (40) with
eccentric key way (5), slide shaft (40) into
eccentric (5) (→fig. 14).
45 Install retaining ring (48) on shaft (40).
46 Install shaft cover (46) on pump (37).
47 Insert and thread screws (44) with
lockwashers (45) into shaft cover (46)
and pump housing (37).
NOTE
Failure to align key on shaft and key way
in eccentric will result in damage to
equipment.
Fig. 13 Fig. 14
42 Position crankrod assembly (7) over top
of pump housing (37) and lower into
pump housing (37) (→fig. 13).
48 Install new cover gasket (36) on pump
housing (37).
49 Install pump cover (35).
50 Install screws (33) with o-rings (34) into
pump cover (35).
51 Tighten screws (33) to a torque of
10 to 15 in-lbf (1.1 to 1.6 Nm).
19

65
66
64
60
63
62
61
72
70
71
69
68
67
73, 74
75
37
52
53
54
55
Fig. 15
52 Insert and thread the housing tube (60)
into pump housing (37).
53 Install hydraulic motor (72) on pump
housing (37) (→fig. 15).
54 Thread hydraulic motor mounting
screws (74) with lock washers (73) into
pump housing (37).
55 Tighten mounting screws (74) to a
torque of 50 to 55 ft-lbf
(67.8 to 74.5 Nm).
56 Install o-rings (71) in motor (72).
57 Place manifold (66) on hydraulic
motor (72).
58 Thread four manifold mounting
screws (65) into manifold (66).
59 Torque screws to 20 to 25 ft-lbf
(27.1 to 33.9 Nm).
60 Install solenoid valve (67) into mani-
fold (66).
61 Tighten solenoid valve (67) to torque of
25 to 30 ft-lbf (33 to 40 Nm).
62 Install pressure reducing valve (70) in
manifold (66).
63 Tighten pressure reducing valve (70) to
torque of 35 to 40 ft-lbf (47 to 54 Nm).
64 Install flow regulator (69) into mani-
fold (66).
65 Tighten flow regulator (69) to torque of
35 to 40 ft-lbf (47 to 54 Nm).
66 Tighten housing tube (60) to torque of
20 to 25 ft-lbf (27 to 33 Nm).
67 Insert retaining ring (61) into second
groove of housing tube (60).
68 Install shovel plug (62) into housing
tube (60).
69 Install spiral retaining ring (63).
70 Install o-ring (54) in outlet pin mounting
hole groove of pump housing (37).
71 Install back-up washer (52) inside outlet
pin nut (55).
72 Install o-ring (53) inside outlet pin
nut (55).
73 Line up outlet pin and thread outlet pin
nut (55) into pump housing (37).
74 Torque to 30 to 35 ft-lbf (40 to 47 Nm).
75 Fill crankcase with SAE 10W30.
76 Install crank case oil dip stick (31)
(→fig. 13, page 19).
77 Torque to 10 to 15 in-lbf (1.1 to 1.7 Nm).
20