5. Carefully inspect ball #17 and seat #18. If worn replace. Note seat #18 can be flipped over to the
other side if worn or damaged. If repacking the unit is necessary always make sure to replace
ball #17 and gaskets 22 and 21.
6. Insert ¼ Hex key into piston valve assembly # 16 and turn counter clockwise to remove piston
valve # 15. Inspect upper ball #13 and carbide seat of piston valve #15. Replace if worn or
damaged. Make sure to always replace upper ball #13 and o-ring #14 if repacking unit.
7. To remove the pump/filter manifold housing use a 5/16" Hex wrench in the 2 mounting bolts
#25. Then unthread transducer #30 from the back of paint/filter manifold.
8. Remove crank housing cover plate # 55 diagram "B".
9. Insert a slotted screwdriver between crank housing # 53, see diagram "B" and fluid manifold # 9
gently pry downwards until a gap can be seen between # 9 and #53. Then slide pump/filter
manifold # 9 from unit.
10. Using a 1" open end or adjustable wrench to remove upper retainer #6.
11. Remove piston rod # 12 by pushing downward with your hand.
12. Inspect upper and lower packings #8 and #11 in place. Do not remove packings to inspect.
Remove only if you intend to replace them.
13. When replacing packings make sure to fill the inside of the packings with "packing grease"
supplied in repair kit 602-475. Also apply grease on o-ring on the outside of the packing to make
insertion easier.
14. Remove upper packing from shipping tool. Insert upper packing in to the top of pump/filter
manifold #9. Packing can only go in one direction.
15. Remove lower packing from shipping tool. Insert lower packing #11 in the bottom of the
pump/filter manifold. Packing can only go in one direction.
16. Thread upper retainer #6 after replacing upper guide #7. Leave hand tight until piston is
installed.
17. Insert upper ball #13 into piston #12 while holding piston upside down.
18. Thread piston valve #15 into piston. Make sure to replace o-ring #14.
19. Using connecting rod item #56 (see diagram "B") to hold piston use a ¼" hex wrench to tighten
piston valve firmly into piston.
20. Replace o-rings #23, 22 and 21 below seat in intake valve and on Piston Guide. Insert lower ball
and seat #'s 17 and 18 and firmly push piston guide into intake valve housing #20.
21. Slide piston # 12 into intake valve housing assembly. Insert piston through lower packing until it
stops. Then thread intake valve assembly into pump/filter manifold. The intake valve housing
assembly will push piston through packings correctly. Once intake valve housing is threaded all
the way use needle nose pliers on the slots of the top of the piston to align slots front to back.
22. Using a 1" open end wrench or adjustable wrench tighten upper retainer # 6 firmly.
23. If connecting rod is not in the down position plug unit in and cycle unit to get connecting rod
into down position.
24. With piston slots aligned slide pump/filter manifold onto connecting rod #56 Diagram "B". Push
pump/filter manifold towards crank housing # 53 to line up dowel pins then thread mounting
bolts #25 through pump filter manifold and thread into crank housing #53. Tighten firmly
with5/16" Hex wrench.
25. Reattach transducer #30 to the back of pump/filer manifold.
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