Service Manual

ProCore SR Series Page 7 -- 7 Gearbox Service
D. Remove bevel gear and tapered bearing cone
(item 5) from housing.
E. Press ball bearing from output shaft.
F. Remove retaining ring (item 2), shim(s) (item 3)
and tapered bearing cup from gearbox housing.
G. Discard removed bearings.
5. Use a press to remove input shaft and bearings from
gearbox housing:
NOTE: Shim set (item 4) is used to adjust input shaft
bearing pre--load. When removing input shaft, take note
of location and number of shims to assist in assembly
process.
A. Remove retaining ring ( item 10) and shim(s)
(item 4) from gearbox input shaft.
B. Press input shaft toward rear opening of gearbox
housing to remove shaft.
C. Remove outer bearing (item 16) from housing.
D. Using a press, remove inner bearing cone (item
15) from input shaft and bearing cup from housing.
E. Discard removed bearings.
6. Thoroughly clean and inspect all gearbox compo-
nents. Replace all worn or damaged parts.
Gearbox Assembly (Fig. 4)
1. Install new bearings and input shaft into gearbox
housing:
A. Press inner bearing cone (item 15) fully onto input
shaft.
B. Insert inner bearing cup (item 15) and outer bear-
ing (item 16) into gearbox housing bores. Make sure
that bearings are pressed fully to shoulder in hous-
ing.
C. Install input shaft into gearbox housing through
rear opening of housing.
D. Install the removed shim(s) (item 4) and retaining
ring (item 10) onto input shaft. If necessary, remove
or add shims so that the shim(s) fit tightly between
the retaining ring and outer bearing. Make sure that
retaining ring is fully seated in shaft groove and that
there is no endplay in input shaft assembly.
IMPORTANT: Before installing output shaft into
gearbox housing, input shaft bearing pre--load
must be checked and, if necessary, adjusted.
2. Check and adjust input shaft bearing pre--load:
A. Use a piece of string and a spring scale to deter-
mine the resistance to rotate the input shaft. Wrap
the string around the input shaft and attach the
spring scale to the string end.
B. Once the input shaft is rotating, the resistance to
continue to rotate the shaft should be from 2 to 3 in--
lbs (0.23 to 0.34 N--m). Repeat this process a few
times until a consistent resistance is determined.
C. If rotating resistance is below 2 in--lb (0.23 N--m),
add additional shim(s) behind the retaining ring (item
4). If resistance is above 3 in--lb (0.34 N--m), remove
shim(s) from behind the retaining ring.
D. Retest rotating resistance after adding or remov-
ing shims.
E. Continue shim placement until input shaft rotat-
ing resistance is consistently from 2 to 3 in--lbs (0.23
to 0.34 N--m).
3. Install output shaft assembly into gearbox housing:
A. Press ball bearing (item 8) onto output shaft.
Make sure that bearing is pressed fully to shaft shoul-
der.
B. Position bevel gear (item 11) and tapered bearing
cone (item 5) inside gearbox housing. Make sure
that bevel gear teeth mesh properly with gear on in-
put shaft. Slide output shaft through ball bearing
opening of housing, bevel gear, bearing cone and
then tapered bearing opening of housing.
C. Insert tapered bearing cup (item 5) into bearing
bore of gearbox housing.
D. Install the removed shim(s) (item 3) and retaining
ring (item 2) into gearbox ball bearing bore. Make
sure that retaining ring is fully seated in housing
groove.
E. Install the removed shim(s) (item 3) and retaining
ring (item 2) into gearbox tapered bearing bore.
Make sure that retaining ring is fully seated in hous-
ing groove.
4. Check that there is no end play in the output shaft
and that output shaft bearings are not pre--loaded. If out-
put shaft end play is determined, add additional shim(s)
(item 3) as needed. If bearing pre--load (drag) is deter-
mined, remove shim(s).
Gearbox
Service