User's Manual

309024 27
Service
Replacing the Primary Pump and/or
Bearing and Pins
NOTE: Refer to Fig. 17 for Steps 1 to 9 except where
noted.
1. Screw the displacement pump (123) into the inlet
manifold (32) so the outlet is facing the back.
2. Screw the connecting rod (121) onto the primary
displacement pump until the cotter pin holes line
up. Install the cotter pin (102d) if the pump has
one; if not, bottom out the connecting rod on the
displacement pump.
3. Pull the connecting rod upward until the displace-
ment pump stops.
4. Screw the air motor (118) onto the connecting rod
until the cotter pin holes line up. Install the cotter
pin (102c).
5. Rotate the air motor until the air inlet port is on the
same side as the air inlet manifold (37).
6. Screw the three tie rods (116) into the air motor
base and torque to 35–50 ft-lb (47–68 N.m).
NOTE: One of the tie rods will run through the lever
arm slot.
7. Push down the air motor and place the tie rods into
the displacement pump tie plate. Tighten the tie
rod locknuts (103).
8. To install the support pin (35c) into the upper
bearing:
a. Remove the two capscrews (16a) from the
support (31a) on the secondary pump (124).
b. Move the lever arm (49) until you can place
the nylon spacers (27c) and support pin (35c)
in line with the bearing in the connecting rod
(121).
c. Lubricate the support pin with Gear Reducer
Oil (43) and tap it into the upper bearing with
the countersinks facing up.
CAUTION
Do not force the pin into place. Check for burrs on
the pin or in the VRHC frame if the pin does not slide
into place. Sand with 500 grit sandpaper between the
countersinks.
d. Torque the two setscrews (59) to 35 in-lb
(4 N.m). See Fig. 18 on page 29.
e. Move the lever arm (49) back into place and
reinstall the two capscrews (16a) onto the
support (31a) of the secondary pump.
02375A
Fig. 17
1
2
118
59
27c
116
103
32
102d
35c
49
102c
121
123
35d
3
14d
27d
17b
1
2
Torque to 60 ft-lb (81 N.m)
Torque to 35 in-lb (4 N.m)
02430