Replacing the O±Ring, Replacing the Gasket

GEAR REDUCER SERVICE (Model 1535)

WARNING

To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin or injury from moving parts, always follow the Pressure Relief Procedure Warning on page 2 before proceeding.

Replacing the O±Ring (5)

1.Remove the four bolts, lockwashers and washers. Pull the pump and gear reducer assembly off the engine.

2.Drain the gear reducer oil by placing a container under it and removing the drain plug with a 22 mm wrench. Replace the o±ring (16) if damaged.

3.Remove the four screws and lockwashers with a 6 mm wrench and pull the gear case off the gear cover.

4.Remove the old o±ring (5). Clean the gear cover and case surface. Lightly coat the new o±ring with grease and install it in the gear case.

5.Follow steps 4 through 6 under Assembling the Gear Reducer if this is all the service required.

Replacing the Gasket (1)

1.Follow steps 1 through 3 under Replacing the O±Ring.

2.Using a 4 mm wrench, loosen the setscrew and pull the gear (4) off the pump with a gear puller.

3.Remove the four screws and lockwashers from the gear cover.

4.Remove the gear cover and gasket (1) from the pump. Clean the gear cover and pump surface. Lightly coat both sides of the gasket with grease and install it on the gear cover.

5.Follow the instructions under Assembling the Gear Reducer if this is all the service required.

Replacing the Oil Seal (10)

NOTE: The oil seal MUST be replaced if removed.

1.Follow steps 1 and 2 under Replacing the O±Ring.

2.Pry the oil seal out of the gear case. Be careful not to damage the gear case.

3.Wipe the inner surface of the gear case clean, then lightly coat it with grease. Place the oil seal into the gear case. Use a socket, placed against the surface of the seal, to push the seal into the case until its top surface is past the ridge in the bore.

4.Follow steps 4 through 6 under Assembling the Gear Reducer if this is all the service required.

Assembling the Gear Reducer

1.Make sure the gasket is properly placed on the gear cover. Refer to step 4 under Replacing the Gasket. Then, install the gear cover on the pump shaft.

2.Align the holes in the gear cover with the holes in the pump. Apply low strength Loctiter (blue) on the screw threads and secure the cover with the four screws and lockwashers. Tighten them oppositely and evenly.

3.Align the gear's slot with the key on the pump shaft and slide the gear onto the shaft, up to the pump's shoulder. Apply low strength Loctiter on the setscrew threads and tighten the setscrew to lock the gear on the shaft.

4.Make sure the o±ring is in place. Refer to step 4 under Replacing the O±Ring. Install the gear case on the cover, aligning the holes, and secure it with the four screws and lockwashers. Tighten them oppositely and evenly.

5.Grease the engine shaft. Align the gear's slot with the key on the engine shaft and slide the gear reducer onto the shaft, up to the engine's shoulder.

6.Secure the gear reducer to the engine with the four bolts and lockwashers.

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