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14308-505
GEAR REDUCER SERVICE (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 W
arning
on page 2 before proceeding.
Replacing the O–Ring
1. Remove the four bolts and lockwashers, and the
four washers, bumpers, and bolts. Then 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 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. 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. Follow steps 1 through 3 under Replacing the
O–Ring.
2. Using
a 4 mm wrench, loosen the setscrew and pull
the
gear of
f the pump with a gear puller
.
3. Remove
the four
screws and lockwashers from the
gear
cover
.
4. Remove
the
gear cover and gasket 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
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. 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 Loctite r 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. 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.