Gear Products Inc N. 161st E. Ave. Tulsa, OK Phone (918) Fax (918)

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Dana Benson
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Gear Products Inc. 1111 N. 161st E. Ave.

1 SERVICE MANUAL Disassembly & Assembly Procedures Worm Gear Swing Drive 003 Series Gear Products Inc N. 161st E. Ave. Tulsa, OK Phone (918) Fax (918)

2 Worm Gear Swing Drive 003 Series (Refer to assembly drawing for item numbers) A. Disassembly Procedure 1. This gearbox contains approximately 2 quarts of EP-0 grease. Drain the grease and dispose of it. 2. Remove the 3/8" hex head capscrews #41 (6 pcs.) from the cover #2. Remove the cover from the worm gear housing #10. After removing the cover from the housing, remove the o-ring #26 from the cover and dispose of the o-ring. 3. Remove capscrews #40 (4 pcs.) from the motor adapter #7. Slide the motor adapter from the housing. Remove the o-ring #24 and dispose of it. 4. Remove capscrews #40 (4 pcs.) from the bearing container #4. Slide the bearing container out of the housing, and remove the shims #6, #35 and #36. Note: These shims must be used when rebuilding the gearbox in order to assure proper pre-load on worm bearings. Remove the o-ring #25 and the seal #21 from the bearing container and dispose of them. Inspect the bearing cup #15 for wear or damage and replace it if required. 5. The Worm #5 can now be removed from the housing #10. Using a soft faced mallet, drive the worm out of the housing by tapping on the hex end of the worm. This will push the worm and bearing cup #17 out the motor end of the housing. Inspect the bearing cones for wear or damage and replace as required. 6. Set the gearbox on a hydraulic press with the output pinion down. 7. Remove the cotter key #33 and the castell nut #13 from the output pinion shaft # Press the output shaft #12 thru the housing and out the bottom of the housing. The lower bearing #18 and the seal #22 will come out with the shaft. Remove the bearing and seal from the shaft. Inspect the bearing for wear or damage and dispose of the seal. 9. The ball bearing #20, spacer #8, worm gear #3, spacer #11 and bearing #18 can now be lifted out of the housing. The bearing cups #19, in the lower bore of housing, should be inspected for wear or damage and replaced if necessary. 10. Check the vent plug #31 and the grease zerk #28 for damage and replace if necessary. 12. Thoroughly clean and inspect all parts for wear or damage. Replace worn and damaged parts as required. Caution: DO NOT REUSE seals, o-rings or damaged bearing cups or cones. End of Disassembly

3 Worm Gear Swing Drive 003 Series (Refer to assembly drawing for item numbers) B. Assembly Procedure Assembly View #1 1. Lay the worm gear housing (large bore up) an a hydraulic press and install one bearing cup #19. Press the cup down until it stops against the step in bore of the housing. Note: Bearing cup must be installed with large taper up. 2. Turn the housing over and install the other bearing cup #19 in the bore of the housing, with the large taper up. Place a bearing cone #18 In the bearing cup. Coat O.D. of the seal #22 with silicone sealant and press the seal into the housing. 3. Set the output pinion shaft #12 on a press (pinion down). Set the housing down over the pinion shaft being careful not to damage the oil seal #22. Place the other bearing cone #18 over the pinion shaft (large end of roller up). Slide a piece of tubing over the pinion shaft down to the bearing cone and press down carefully until there is a light preload on the bearings. Note: Make sure to press on inner race of the bearing. 4. Slide spacer #11 over the pinion shaft down to the bearing. 5. Place worm gear #3 on the pinion shaft making sure that splines in gear and on shaft are in line. Slide worm gear down to spacer # Slide spacer #8 onto the pinion shaft down to the worm gear. (Flat side down against the worm gear). 7. Place ball bearing #20 on the pinion shaft pushing it down against the spacer #8. 8. Install the castell nut #13 on the pinion shaft. Tighten the castell nut until there is no end play in the pinion shaft, then tighten until the next castillation is in line with the cotter key hole in the pinion shaft and install the cotter key #33. Assembly View #2 9. Press the bearing #14 onto the hex end of the worm #5 making sure that the bearing is down against the shoulder on the worm. Press bearing #16 down against the shoulder on the motor end of worm. The small taper of the bearings should be to the outside on both ends of the worm. 10. Slide the worm #5 into the housing #10 by inserting the hex end of the worm into the motor end of the housing and turn the worm counter-clockwise until the worm is centered in the housing. 11. Install the bearing cup #17 into the motor end of the housing. The bearing cup should be pushed in until it is flush with the face of the housing. 12. Install the o-ring #24 in the groove on O.D. of the motor adapter #7. Coat the o-ring with clean oil. 13. Using 4 capscrews #40 and lockwashers #50, bolt the motor adapter to the housing. As the adapter is pulled down it will push the bearing cup into the right location in the housing. Torque these bolts to 39 foot pounds.

4 14. Coat the O.D. of the seal #21 with silicone sealant and press the seal into the bearing container #4. Press the bearing cup #15 into the bearing container. Place the o-ring #25 in the groove in the O.D. of the bearing container and coat the o-ring with clean oil. 15. Place 1 shim #35 and 2 shims #36 on the bearing container, and push the bearing container into the housing being careful not to damage the seal. Using capscrews #42 and washers #58 secure the bearing container to the housing. Torque these capscrews to 39 foot pounds. After bearing container is bolted to the housing check for proper pre-load on the bearings by moving the worm end to end. The end play should be ". It is very important that the pre-load is property adjusted so that the unit can be turned thru by hand (Hex Drive End) but that there is not too much end play in worm. Shims #6, #35 & #36 can be used to set the proper preload on the worm bearings. Assembly View # Install vent plug #31 in the 1/8" N.P.T. hole in the bottom of the housing, and pipe plug #29 in the end of the housing opposite of the worm. 17. With the gearbox setting in the pinion down position, install 2 quarts of EP-0 grease. 18. Place o-ring #26 in the groove in the O.D. of the housing cover #2. Coat the o-ring with clean oil. 19. Place the housing cover #2 on the housing making sure that the cover is down over the ball bearing #20 and that the bolt holes are in line with the threaded holes in the housing. Using 6 hexhead capscrews #41 and washers #58 secure the cover to the housing. Torque the capscrews to 39 foot pounds. Install a #29 pipe plug in the 3/8 N.P.T. hole in the cover and a #32 plug in the 1/8-27 hole in the center of the cover. Assembly View # Install the motor using the motor gasket #34. Assembly View # Slide eccentric ring #49 down over the output pinion teeth onto the housing hub. (Holes in eccentric ring should be toward the pinion teeth). 22. Install the grease zerk #28 in the threaded hole in housing hub. Using a hand type grease gun pump grease into zerk. (approximately 6 pumps) Caution: Too much pressure or grease may damage the seal. End of Assembly

5 Assembly View #1

6 Assembly View #2

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