SprayTECH GPX 1600 Owner'S Manual Download Page 12

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Replacing the Gears

1. Perform the Pressure Relief Procedure.
2. Using a Phillips screwdriver, remove the four front cover

screws. Remove the front cover..

3. Using a 7/8” open-end wrench, loosen and remove the

fluid hose from the fitting on the back of the fluid section.

4. Locate the four socket screws that secure the pump

housing to the gear housing. Two are at the inside top of
the pump housing and two are located on the external
bosses at the bottom of the pump housing.

5. Using a 1/4” hex wrench, remove the four socket screws

that secure the pump housing to the gear housing.

6. Slide the pump housing assembly away from the gear

housing.

7. Remove and clean the housing gasket. Replace if

damaged.

8. Remove the gear assembly and the 1/4” thrust balls from

within the bearing bores that support the gear.

9. Inspect the gears for excessive wear and replace if

damaged or worn. If the gear assembly is replaced,
replace the two thrust balls as well.

10. Inspect the pinion gear on the end of the drive shaft for

wear. Replace if damaged or worn (refer to the “Servicing
the Clutch Assembly” procedure in this section).

11. Inspect the output gear and the two thrust washers on the

end of the crankshaft in the pump housing for wear. This
gear is permanently attached to the crankshaft and pump
housing. If this gear is worn, the pump housing must be
replaced.

12. Replace the thrust washers if worn. If the pump housing

assembly is replaced, replace the thrust washers as well.

13. Coat each of the thrust balls with a generous amount of

grease. Install the thrust balls — one in the gear housing
bore and one in the pump housing bore.

14. Coat the gear assembly with fresh Lubriplate GR-132

grease. Insert the gear assembly into the bore in the
pump housing, pinion end first.

15. Generously coat both faces of each of the crankshaft

thrust washers with grease.

NOTE: If any of the gears are worn and require

replacement, check the grease in the gear
housing for metal particles or shavings.
Remove the contaminated grease. Replace the
grease that has been removed with fresh
Lubriplate GR-132 grease.

NOTE: If replacing the pump housing , first remove

the fluid section, slider housing, and slider
assembly from the pump housing (refer to the
“Replacing the Slider and Slider Housing”
procedure in this section).

Housing Gasket

Gear Housing

Thrust Ball

Thin Thrust Washer

Thrust Ball

Front

Cover

Pump Housing

Gear

Assembly

Thick Thrust

Washer

Pump Housing
Socket Screw

Front Cover

Screw

16. Place the thick thrust washer onto the crankshaft up

against the gear hub. Next, place the thin thrust washer
up against the thick washer on the crankshaft.

17. Place the housing gasket over the gear housing dowel pins.
18. Carefully place the pump housing assembly in front of the

gear housing assembly, lining up the gear housing dowel
pins with their corresponding holes in the pump housing.
Slide the pump housing onto the gear housing until there
is no gap between the housings and gasket.

Do not force the pump housing and gear housing together.

19. Locate the four socket screws and lock washers that secure

the pump housing to the gear housing. The longer screws
(2.25”) are fastened into the top internal holes. The shorter
screws (2”) are fastened into the bottom external bosses.

20. Using a 1/4” hex wrench, snug and tighten the socket

screws in a crossing pattern. Torque to 200–230 in./lbs.

21. If the slider, slider housing, and fluid section were

removed, reinstall by following the steps in the “Replacing
the Slider and Slider Housing” procedure in this section.

22. Position the front cover over the pump housing. Secure

the front cover using the four front cover screws.

23. Using a 7/8” open-end wrench, attach the fluid hose to the

fitting on the back of the fluid section. Tighten securely.

Servicing the Clutch Assembly

Removing/Replacing the Clutch Hub and
Armature Assembly

1. Perform the Pressure Relief Procedure.
2. Using a 7/8” open-end wrench, loosen and remove the

fluid hose from the fitting on the back of the fluid section.

3. Hold the transducer tube with a pliers to prevent it from

rotating and turn the transducer nut counterclockwise
using a 3/4” open-end wrench. When the nut disengages
the filter housing, carefully remove the transducer from the
filter housing.

4. Locate the wire that exits the rear of the electronic

pressure control (EPC) housing and connects to the wire
harness on the engine. Disconnect this wire from its
connector at the engine wire harness.

5. Using a 1/2” wrench, remove the four hex screws and lock

washers that secure the clutch housing to the gear housing.

6. Using a 9/16” socket, remove the two hex screws that

secure the gear housing to the cart.

7. Slide the pump and gear housings away from the engine

to disengage them from the clutch housing.

Clutch Armature

Clutch Hub

Taper Lock Bushing

Gear