Whale Gusher Galley Mk3 Service Kit

Intro

The following are the steps I developed when installing service kits for my two Whale Gusher Galley Mk 3 foot pumps. These pumps have been manufactured since 1984, so I suspect they will be found on most all of our boats. The service kit is part number AK0553. It is widely available. I bought my kits on eBay. They looked like old stock, but the parts were fine. I have serviced two pumps, so I have limited experience. The following procedures worked for me. But, they may not all be correct (please mention any needed corrections) and certainly are not the sole way to accomplish this task.

Naming Parts

I found a pump exploded view with names for most of the kit parts. I could not find a view which names each pump part. So, I made up some part names to help with my description. My inventions are listed below and shown in Figure 1:

• Pump body parts:
  

  Figure 1
  • Front cover
  • Body
  • Rear cover
• Piston parts:
  • Font piston plate
  • Piston
  • Rear piston plate
  • Piston bolt
  • Piston bolt O-ring/gasket
• Valve assembly parts:
  • Valve body
  • Valve seat

Disassembly

Figure 2

1. Remove four screws at pump lever. Keep these screws separate for reassembly. They are ¼” shorter than the front and rear cover screws. See Figure 2.
2. Remove rear cover. Remove the six rear cover screws. Front and rear cover screws are the same size and can be co-mingled for reassembly. Pry the rear cover from the pump. The large O-rings on the valve bodies make pressure fits on the rear and front covers. See Figure 3.