INSTALL ALL KIT COMPONENTS TO INSURE OPTIMUM PERFORMANCE OF THE REPAIRED PUMP.
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1 Repair Parts Sheet JL-4GBS Gas Power Units L1918 Rev. C 2/99 For Date Codes Beginning With "O" INSTALL ALL KIT COMPONENTS TO INSURE OPTIMUM PERFORMANCE OF THE REPAIRED PUMP. Repair parts that are included in Repair Parts Kits are marked throughout this sheet as follows: Seal Kits Used whenever pump unit is disassembled for service. Contains seals only. Overhaul Kits Used for complete rebuild of pump. The Overhaul Kit includes a complete Seal Kit. Seal and Overhaul Kits include repair parts for the control valve. Also available... Spark Plug - part number DA Spark Plug Wrench - part number DA Figure 1A - Basic Pump Assembly Figure 1B - Basic Pump Assembly Figure 2 - Pumping Assembly Figure 3 - Piston Block Assembly CONTENTS Figure 4 - Bypass Valve Assembly Figure 5 - Dump Valve Figure 6 - Selector Valve
2 Read Owner's Manual Before Operating. Figure 1A - Basic Pump Assembly , 57, 87, 90 40, 42 Torque Items 40 and 41 to ft-lbs (19-22 Nm). 54, 58, 88 54, 58, Torque to ft-lbs (37,9-43,4 Nm). Apply Loctite 242 to mounting bolts of motor and valve. 89, 57, , , , 8 REPAIR PARTS LIST FOR FIGURE 1A Item Part Number Qty. Description Item Part Number Qty. Description 2 DA Liter Reservoir 39 Y Gasket 8 C Magnet 40 CCA A 6 Screw (dump only) 9 A Hex Plug CCA A 3 Screw (selector only) 12 DA HP Gas Engine 41 CCA A 2 M8x80 Screw (selector only) 13 CCA A 2 Cap Screw 42 C Gasket 14 DA Honda Engine Spacer DC Manifold (selector only) 18 CU Spring 44 A Hex Plug 19 DA Woodruff Key 45 DA Elbow Fitting 27 B O-Ring 54 CH Male Adaptor 30 DA SR 1 Connector Tube 84 DA Decal (dump only) 30 DA SR 1 Connector 57 DA Blue Cable Tie Tube(relief only) 87 F Thread Protector 87 F Thread Protector 88 F Flare Fitting 1 58 DA Red Cable tie 89 CB Male Connector 31 B O-Ring 118 DA Foot 32 B Back-Up Ring 119 DA Tube Nut 120 B Washer 38 DA SR 1 Dump Valve Block 121 DA Washer DA SR 1 Selector Valve Block 122 B Bolt 2
3 Figure 1B - Basic Pump Assembly , 33 JAWS OF LIFE RES Pressure Hose JAWS OF LIFE RES Tank Hose Note: Pumps with dump valves use one (1) of each hose. Pumps with selector valves use two (2) of each hose. Torque to 3-4 ft-lbs (4-5 Nm) , 16, Torque to ft-lbs (38-43 Nm). 3, 4 23, 25 REPAIR PARTS LIST FOR FIGURE 1B Item Part Number Qty. Description Item Part Number Qty. Description 3 DA SR 2 Filter Assembly 33 B O-Ring 4 DA SR NPT Pipe 57 DA Blue Cable Tie Nipple 7 CBE Screw 58 DA Red Cable Tie 10 DA Level Gauge 85 DA Hose Ass y. - Pressure 15 CCA A 1 M8 Set Screw 86 DA Hose Ass y. - Tank 16 CBE D 1 Hex Nut 95 DA Inhalation Hazard Decal 17 DA Spacer 96 DA Hot Surface Decal 22 DA Roll Cage Weldment 97 DA Flammable Mat. Decal (not shown) 23 CBE A 4 Hex Bolt 98 DA Power Warning Decal 25 CAE A 4 Flat Washer 99 DA CE Label 3
4 Figure 2 - Pumping Assembly IMPORTANT: When servicing any of the pump components, a complete Seal Kit must be installed to eliminate the potential for failure resulting from the reuse of original seals. CAUTION Parts have machined surfaces. Be careful when handling to avoid damaging parts. NOTE: Set Item 34 to psi 1 Use Loctite 545 for pipe fittings. Apply Loctite 242 to threads. Torque to ft-lbs. Use Loctite for pipe fittings. Apply Loctite 242 to threads. Torque to ft-lbs. A Apply Loctite 242 to threads. Use Loctite 545 for pipe fittings. A Apply Loctite 242 to threads. 25 Use Loctite 545 for pipe fittings. 4
5 , ,19 7 SECTION "A-A" 35 REPAIR PARTS LIST FOR FIGURE 2 Item Part Number Qty. Description Item Part Number Qty. Description 1 DA SR 1 Top Plate 1 19 DA Thrust Race 3 DA Eccentric Shaft 25 Y Male Branch Tee 4 DA Needle Roller Bearing 1 26 CCA A 12 Mounting Bolt (M8 x 65) 5 DA SR 2 Piston Block Assembly (See Fig. 3 for details.) 27 DA Tube Assembly 6 BSS4725D 2 Ring 2 28 DA Tube Assembly 7 1 Retaining Ring 2 29 F Street Elbow CCA A 8 DA Cam Bearing 2 30 C Fitting 9 DA SR 1 Hex Cam 2 31 B Elbow 10 DA SR 1 Bottom Plate 3 32 DC566950SR 1 Bypass Valve Assembly 4 (See Fig. 4 for details) 11 DA Lip Seal 1 33 DA Hose Fitting 14 DA Bottom Bearing 3 34 DA SR 1 Relief Valve Assembly 17 B O-Ring 35 DA Washer 18 DA Thrust Bearing 5
6 Figure 3 - Current By-Pass Assembly Figure 4 - Previous By-Pass Assembly Torque to ft-lbs. (38-46 Nm)
7 Figure 5 - Piston Block Assembly Figure 6 - Relief Valve Assembly
8 REPAIR PARTS LIST FOR FIGURE 3 Item Part Number Quantity Description Item Part Number Quantity Description 7 B Back-up Washer 9 B EPR O-Ring 8 B O-ring 10 DC566950SR 1 Complete By-pass Valve Assembly REPAIR PARTS LIST FOR FIGURE 4 No longer serviced. Order DC566950SR complete bypass valve assembly. REPAIR PARTS LIST FOR FIGURE 5 Item Part Number Quantity Description Item Part Number Quantity Description 2 DA Conical Spring 8 B EPR O-Ring 3 See Fig. 3, Item 5 1 Piston Block Assembly 13 B EPR O-Ring REPAIR PARTS LIST FOR FIGURE 6 1 CCA A 1 Set Screw 7 DA Compression Spring 2 DA Nut 8 DC Ball Guide 3 DA Threaded Body 9 B /32" Ball 4 CCA C 1 Set Screw 10 4See Fig. 3, Item 3 1 Relief Valve Assembly 5 DA Plunger 11 B EPR O-Ring 6 DA Spring Guide 12 B Spring Pin 8
9 Figure 7 - Dump Valve Loctite REPAIR PARTS LIST FOR FIGURE 7 Item Part Number Quantity Description Item Part Number Quantity Description DA SR 1 Complete Valve 5 DC SS Screw Assembly 1 DC SS Washer 6 DC Valve Handle 2 B Back-Up Washer 7 B EPR O-Ring 3 DA Valve Stem 9 B Ball Items included in and available only as part of Repair Kit VM2K1E. Note: The pump seal kit, JL4GK, includes a VM2K1E valve repair kit. 9
10 Figure 8 - Selector Valve Assembly Torque Item 7 to ft-lbs. (38-46 Nm). Loctite
11 Item No. Part Number Quantity Description REPAIR PARTS LIST FOR FIGURE 8 Item No. Part Number Quantity Description 1 DC Screw 15 B EPR O-Ring 2 DC Washer 16 CH542950SR 1 Disc Assembly 3 DC Valve Handle 17 B Roll Pin 4 DC Disc 18 DA Shear Seal 5 B " Ball 19 B Back-Up Washer 6 A Spring 20 B O-Ring 7 B Socket Hd. Cap 22 CB Spring Screw 8 DC Roll Pin 23 CH Body 9 CB Valve Cap 24 B Screw 10 B EPR O-Ring 25 B O-Ring 11 CB Bearing Plate 27 DA Adaptor Block 12 CB Bearing 28 A Pipe Plug 13 DC Shaft 29 DA Pipe Plug 14 B Back-Up Washer 31 B Roll Pin Items included in and available only as part of Repair Kit DA KE. Note: The pump seal kit, JL4GK, includes a DA KE valve repair kit. 11
12
Tech. Services: (800) Fax: (800) Order Entry: (800) Fax: (800)
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2525 GARDNER ROAD, BROADVIEW, IL 60155 1.800.323.9114 Outside U.S. 1.708.865.1500 www.tksimplex.com G5 SERIES ELECTRIC POWER PUMP PARTS IDENTIFICATION MANUAL Reference # - 54247 Rev. - A Date - 10/08 This
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2525 GARDNER ROAD, BROADVIEW, IL 60155 1.800.323.9114 Outside U.S. 1.708.865.1500 www.tksimplex.com G4 SERIES ELECTRIC POWER PUMP PARTS IDENTIFICATION MANUAL Reference # - Rev. - A Date - 05/10 This illustration
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2525 GARDNER ROAD, BROADVIEW, IL 60155 1.800.323.9114 Outside U.S. 1.708.865.1500 www.tksimplex.com G3 SERIES ELECTRIC POWER PUMP PARTS IDENTIFICATION MANUAL Reference # - 54246 Rev. - A Date - 10/08 This
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