16
308–530
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
(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.
