Graco Inc 800-700, 800-699 Gear Reducer Service Model, Replacing the O-Ring, Replacing the Gasket

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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 of f 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 of f 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, remove retaining bolt, lockwasher, flat washer 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 Loctite r (blue) on the screw threads and secure the cover with the four screws and lockwashers. T ighten 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. Tighten the retaining bolt, lockwasher and flat washer 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. T

ighten 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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Contents 1535 2040 2540 Rev a800-698, Series a 800-699, Series aIndex TermsGeneral Safety Pressure Relief ProcedureSpray Gun Safety Devices Moving Parts HazardHose Safety Equipment Misuse HazardFuel and Emission Hazards System PressureInstallation Set Up1535 Check for Shipping DamageStartup Installing and Changing Spray Tips Trigger Safety LatchFollow the Pressure Relief Procedure Maintenance Pressure Relief ProcedureSHUTDOWN, Flushing Storage Interval What to doTroubleshooting Chart ProblemHydra-Cleanr1535 Pressure Washer Parts DrawingParts List Part Description QTYHydra-Cleanr2040 Pressure Washer WASHER, Flat 3/8 804-249 Assembly incl 802-139 Hydra-Cleanr2540 Pressure Washer FILTER/STRAINER Gear Reducer Service Model Replacing the O-RingReplacing the Gasket Replacing the Oil SealGear Reducer Model BearingGear Reducer Service Models 2040 Replacing the Oil SealsGear Reducer Models 2040 Pump Assembly, 1500 psi Kit Repair Kit Description Qty 804-102 804-101Pump Assembly, 2000 psi Kit Repair Kit Description Qty 804-100 804-096Pump Assembly, 2500 psi Kit Repair Kit Description Qty 804-098 804-234 STUD, Retaining 6mm x 64,5mm804-097 Servicing the Valves Pump Service ModelServicing the Seals Reassembly Torque Chart Pump Part Thread Tool SizeServicing the Plungers Servicing Crankcase SectionPump Service Models 2040 308-530 ReassemblyServicing the Pumping Section Servicing the Seals and V-PackingsReassembly Packing ModelsHigh Pressure Seal Models Low Pressure Seal-All ModelsAccessories Downstream Chemical Injector KIT 800-117Technical Data ModelImportant Phone Numbers Graco WarrantyGraco INC. P.O. BOX 1441 MINNEAPOLIS, MN
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