HUB CITY BEVEL GEAR DRIVES

Maintenance Instructions
General Note — These instructions contain information common to 16
17
more than one model of Bevel Gear Drive. To simplify reading, 10
similar models have been grouped as follows:
GROUP 1 — Models 11, 150, 165, 175, 66 (illustrated), 65, 88, 600, 12
800, 810, 850, 1000, 1010 and 1200. 30
GROUP 2 — Models 790, 920 (illustrated), 950, 1050 and 1250.
GROUP 3 — Models M2 and M3. 15 5
GROUP 4 — Models AD1, AD2, AD3, AD4 & AD5. 14
NOTE: For PINION SHAFT disassembly instructions for Models 29
1010 and 1200, follow the Group 2 instructions. For PINION 3
SHAFT disassembly instructions for the Model 790, follow the 29 4
Group 1 instructions. 13
It is advisable to periodically inspect your Bevel Gear Drive for any signs
32
of impending service. Spare or replacement parts can often be ordered 33
31
and obtained before disassembly is necessary, thus minimizing machine
down-time. The following symptoms can be inspected visually without 9 17
disassembly and may, in some cases, indicate extensive maintenance 6
procedures. 17
2
31

31
9
23 1
28 32
19
26
17
24 20
28 21

6 18
7

2 22
23
31
FIGURE 4 – Group 1 Drives

Oil leaking from pinion housing, caps, cap screws or pipe plugs—
1 might be corrected by retightening or removal and recoating with pipe
17 sealant before tightening. If this does not correct the leaking condition,
disassembly will be necessary to replace O-rings.
33 High internal operating temperature (above 200° F.)—could indicate
that unit was being overloaded and should be replaced entirely with a
larger capacity unit. Damaged bearings or inadequate oil level can also
25 cause heat build-up.
27 Oil leaking from seals—indicates that shaft and/or seals are worn and
need replacing. Keep dirt and foreign particles off shafts in the area of the
8 seals to minimize wear. Note: On initial run of new unit or after a new
replacement of seals, some lubricant leakage is normal for the first few
hours of running time until seals seat against the shafts. If condition
persists, seal replacement will be necessary.
Excessive end play of shafts—if there is a noticeable (.005” or more
5 measurable) shaft movement when couplings are removed and shaft is
moved back and forth, it is an indication of bearing wear. Removing
10
shims between caps and gear case can usually correct the condition and
15 14 avoid bearing replacement.
30 Excessive backlash—might indicate worn gears which often may be
15
3 readjusted, instead of replacing.

4
IMPORTANT
13 In the initial factory assembly, Loctite® was used on the threads of all cap
12 screws. If any screws are removed, a new application of Loctite® is nec-
11 essary or lock washers must be installed. Note—Screw threads and
FIGURE 3 – Group 2 Drives
threaded hole must be degreased before the application of Loctite®.

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HUB CITY BEVEL GEAR DRIVES

Maintenance Instructions
Group 2 Drives—Secure Pinion Shaft (10, Figure 3) with a vise, on shaft
WARNING extension and remove cap screws from Seal Carrier (11), and remove it
For safe operation and to continue the unit warranty, when installing, and gasket from Pinion Housing (3). Loosen Lock Nut (12) and remove
reinstalling, or replacing a factory installed fastener for servicing from pinion shaft. Remove remaining pinion assembly from the vise and
purposes, or to accommodate the mounting guards, shields or other light place inner flange surface of the Pinion Housing (3) on the anvil of a
load imposing devices, or for mounting the unit, it becomes the press. Push shaft through pinion housing, thereby releasing Outer
responsibility of the customer or user to properly determine the quality, Bearing Cone (13). Whenever gear set is changed, it is recommended
grade of fastener, thread engagement, load carrying capacity, tightening that the Inner Bearing Cone (14) be replaced. If bearings are to be
torque, and the means of torque retention. replaced, remove Bearing Cups (15) from Pinion Housing (3) with a puller
tool or if one is not available, gently tap opposite back sides of the
DISASSEMBLY PROCEDURE bearing cups with a flat punch so that they are removed evenly and no
damage occurs to pinion housing.
CAUTION Group 3 Drives (not illustrated)—Disassembly of the pinion shaft
The exterior threaded holes on this drive are for mounting the drive or assembly is essentially the same as Group 1 Drives above except a snap
drive accessories (couplings, sprockets, etc.). They are not to be used for ring must be removed instead of a lock nut so that bevel gear can be
lifting the drive or any driver/driven equipment. removed. M2 and M3 Drives have ball bearings instead of tapered
WARNING bearings and they may be removed easily from pinion housing after shaft
Make certain that the power supply is disconnected before attempting to has been pressed out. It is necessary to replace pinion housing seal due
service or install the unit, or remove any components. lock out the power to probable damage during disassembly procedure.
supply, and tag it to prevent unexpected application of power.
CROSS SHAFT DISASSEMBLY
WARNING Group 1 Drives—Cross Shaft Assembly (7, Figure 4) is disassembled by
Wear protective clothing and eye shields when installing or maintaining placing Shaft (18) in a press with sleeve between anvil and gear.
unit and machine. Figure 5 shows the use of a sleeve to support gear at hub. On certain
types of bevel gears it is recommended that this tool be used to protect
Group 1, 2 and 3 Drives (Refer to Figures 3 and 4 unless otherwise
gear teeth. This tool may be obtained from Hub City or machined for the
noted.)
purpose in your shop.
1. Disconnect Bevel Gear Drive from drive motor, couplings or driven
Push shaft through Bearing Cone (19) and Bevel Gear (20). Invert shaft
shafts to guard against personal injury. Remove all sprockets, or
and rest Bearing Cone (21) on sleeve and anvil or, on some models, on
sheaves from Bevel Gear Drive shafts with a puller tool to prevent
Spacer (22) and push shaft through bearing cone. If bearings are to be
accidental damaged to shafts. Remove all keys from keyways.
replaced, remove Bearing Cups (23) from Open Caps (6 and 9) with a
2. Remove Pipe Plug (1) from bottom of Gear Case (2) and drain all
puller tool or, if one is not available, gently tap opposite back sides of the
lubricant from unit, preferably while unit is warm.
bearing cups with a flat punch so that they are removed evenly and no
WARNING damage occurs to caps.
Oil, housing, and other components can reach high temperatures during
operation, and can cause severe burns. Use extreme care when remov-
ing lubrication plugs and vents while servicing the unit.
3. If old seals are to be salvaged, cover keyways with cellophane tape,
plastic shim stock or paper. Remove cap screws from Pinion Housing
(3) and CAREFULLY remove Pinion Shaft Assembly (4). Be careful to
keep bearings clean and not to damage Gear (5) teeth.
4. Remove cap screws from Open Cap (6) which is opposite the gear side
of Cross Shaft Assembly (7, Figure 4) and Output Sleeve Assembly (8,
Figure 3) and remove, being careful to keep bearings clean and
preventing damage to gear teeth. Slip open cap with seal off cross
shaft or output sleeve.
5. Remove cap screws from Open Cap (9) on the gear side of Gear Case
(2) and remove cap and shims. This completes disassembly of
sub-assemblies.

PINION SHAFT DISASSEMBLY

Group 1 Drives—Secure Pinion Shaft (10, Figure 4) with a vise, and
remove Lock Nut (12) and washer from shaft. Place pinion assembly in a
press with threaded end of shaft up and back side of Bevel Gear (5)
supported. Remove gear by pressing out.
Support outer flange surface of Pinion Housing (3) on press anvil and
push threaded end of pinion shaft through housing, thereby removing
Inner Bearing Cone (14), Outer Bearing Cone (13) Spacer Washer (15),
Seal (16) and Shaft (10) from pinion housing. Note—disassembly of the
pinion shaft from the housing will cause damage to the seal and seal must
be replaced. If bearings are to be replaced, see Group 2 instructions FIGURE 5 – Pressing Shaft out of Bearing and Gear
below.

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 HUB CITY BEVEL GEAR DRIVES

Maintenance Instructions
NOTE: All cross shafts in Group 1 Drives are shouldered. Bearing Cones ASSEMBLY PROCEDURE
and Gears must ALWAYS be removed by moving them away from the
1. All parts including the gear case, should be cleaned thoroughly with an
shoulder.
approved, non-flammable, non-toxic solvent. Any accumulation of
sludge deposits or corrosions should be removed. Whenever pinion
Group 3 Drives (not illustrated)—Disassembly procedure for Models
housing and caps are removed, it is recommended that seals and gas-
M2 and M3 cross shafts is similar to Group 1 above except that a spacer
kets be replaced. These and other miscellaneous items are included in
is located between the bevel gear and the bearing. The spacer is
each Drive Repair Kit. (See Parts Lists).
removed with the gear. These models have ball bearings which are
Before reassembly, examine pinion and cross shafts or output sleeve
easily removed from caps.
for grooving in the shaft seal areas. If the shafts are to be reused,
polish out any imperfections with a fine grade of Emery Cloth. The
OUTPUT SLEEVE DISASSEMBLY polishing motion should be circumferential, not axial or spiral in
Group 2 Drives—Bearing (24, Figure 3) is removed from Output Sleeve direction.
(25) on the side opposite the gear (G.O. side) by placing inner bearing 2. Replace Bearings Cups (15 and 28, Figure 3) and (23 and 29, Figure
race on the press anvil and pushing sleeve out of bearing. If Bearing (26) 4) in pinion housing and open caps being careful to remove any foreign
on the gear side needs to be replaced, it can be removed by tearing apart particles in the counterbore. Bearing cup must seat squarely in
bearing and removing inner bearing race with a gear puller. counterbore (Groups 1 and 2 only). If cup must be tapped into place,
If gear side Bearing (26) is to be salvaged and reused (because of a use a rubber hammer or piece of wood to protect cup surfaces. Do not
replacement of ring gear or output sleeve), it must be gently tapped off insert seals at this time.
sleeve with a flat punch after drilling several opposing holes (max. 3/16” 3. When reassembling Pinion Shaft Assembly (4, Figures 3 and 4), Cross
dia.) in flange of output sleeve as shown in Figure 6. When enough Shaft Assembly (7, Figure 4) and Output Sleeve Assembly (8, Figure 3),
clearance is obtained between bearing and output sleeve, insert a refer to Figures 3 and 4 so that all parts are included in their proper
bearing puller and complete bearing removal. It is good practice to position. Be sure that parts are pressed tightly against one another and
remove the gear side bearing from the output sleeve if Ring Gear (27) has that no foreign material is included between them.
to be replaced because the bearing could easily be contaminated with
metal fragments when ring gear rivets are removed.

HOLES
3/16" DIA.
MAX.

FIGURE 7 – Reassembly of Gear FIGURE 8 – Pinion Assembly

and Bearing Cone Adjustment

Figure 7 shows the recommended method of pressing the Bearing Cone (1)
onto Shaft (2). An Inserting Tool (3) is shown pressing evenly on the
FIGURE 6 – Gear Side Bearing Removal bearing inner race. This tool may be obtained from Hub City or machined for
the purpose in your shop. A substitute inserting tool may also be made from
Ring Gear Removal—Rivets must be removed by either drilling through tubing which would have an I.D. sufficient to accept the shaft and an O.D.
rivet heads on one side and tapping them out or machine off rivet heads no larger than the inner bearing race.
in a lathe and then tap them out. Important — extreme care should be
taken to prevent damage to output sleeve. CAUTION
NOTE: On model 790 the Ring Gear is keyed to the output sleeve. Contact on the cage of the bearing or using the bearing cup to press the
bearing on will damage bearing. If it is impossible to install the bearings as
INSPECTION recommended above, the alternate method would be to heat the bearing (to
Examine all seals for wear or damage and press out of open caps, pinion increase the I.D. temporarily) and gently tap opposite sides of the bearing
housings and seal carrier if replacement is necessary. Inspect all other inner race with a flat punch without damaging bearing.
part for damage or wear before proceeding to reassembly.

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HUB CITY BEVEL GEAR DRIVES

Maintenance Instructions
Group 1 Drives—Assembly of Cross Shaft Assembly (7, Figure 4) is grooves in caps and pinion housings. Apply grease liberally on surface of all
essentially the reverse of the disassembly procedures except that when O-rings before assembly into housings.Install Open Cap (9, Figures 3 and
installing Bevel Gear (20) on shaft, first insert woodruff key. Gear is then 4) on the gear side of Case (2, Figures 3 and 4) with 3 shims. Fasten caps
heated in hot oil and then installed on shaft where it will cool and shrink fit. and shims to gear case by torquing down cap screws securely. Insert Output
The Pinion Shaft Assembly (4, Figure 4) is assembled as follows: Insert Sleeve Assembly (8, Figure 3) or Cross Shaft Assembly (7, Figure 4) care-
Spacer (15) on Pinion Shaft (10). Press Outer Bearing Cone (13) on shaft fully through opening in case and into open caps. Install 3 shims and Open
using inserting tool. Place threaded end of shaft into Pinion Housing (3) and Cap (6, Figures 3 and 4) on the case side which is opposite the gear with
press Inner Bearing (14) over shaft and into pinion housing with inserting cap screws and torque down all screws evenly.
tool. Install woodruff key and press Pinion Gear (5) on shaft. Assemble Bearings are then adjusted by removing or adding gaskets until the
Pinion Washer (30) and Lock Nut (12) on shaft. Secure assembly in a vise bearings bind and then add one gasket at a time until shaft or sleeve rotates
as shown in Figure 8 and tighten lock nut enough to draw down gear and freely, with no end play. Note—Position of gear will be closer to center if the
washer until the bearings bind. Nut is then backed off slightly (approx. 1/4 number of shims on each end cap does not vary by more than one.
turn). Release pinion shaft from the vise and rap nut and shaft end sharply Insert Pinion Shaft Assembly (4, Figures 3 and 4) carefully into Case (2)
with a rubber mallet while supporting pinion housing on vise (see Figure 9). using 3 shims and cap screws. Gear backlash is adjusted by moving shims
This will free up the bearings so that they will rotate freely with no noticeable from the cross shaft or output sleeve open cap on the gear side to the side
end play. Do not install seals at this time. See FINAL ASSEMBLY AND opposite the gear until gears rotate freely, with no noticeable backlash. At
BACKLASH ADJUSTMENT section to complete assembly. this point, move 2 shims back to the gear side end cap and the gears will
then be properly adjusted. Note—if there are not enough shims left in open
cap opposite gears to move 2 shims back—further gear adjustment must be
made by removing 2 shims from between the pinion housing and case and
repeat the entire procedure listed in this and two preceding paragraphs.
When bearings and gear backlash have been properly adjusted, remove cap
screws a final time, clean threads on screws and in holes with degreaser. Coat
threads with Loctite®. If Loctite® or equivalent is not available, use lock washers
(not supplied) behind screw heads. Torque down all screws evenly.

OIL SEAL INSTALLATION

Group 1, 2 and 3 Drives—Oil seals
(30 and 31, Figures 3 and 4) and
(16, Figure 4) can now be installed in
open caps and pinion housings. Slip
Seal (1, Figure 10) over tapered end
of Pilot Sleeve (2, Figure 10),
making sure that the spring loaded
lip of the seal is facing toward the
Bevel Gear Drive. Slip pilot sleeve
over shaft and down until end of
sleeve is against bearing. Install
Seal Driver (1, Figure 11) over pilot
sleeve and tap seal down sleeve
until it is seated in housing or cap.
FIGURE 9 – Pinion Assembly FIGURE 10 – Oil Seal Remove seal driver and pilot sleeve.
Adjustment Installation These installation tools are available FIGURE 11 – Oil Seal
from Hub City.
Group 2 Drives—The Output Sleeve Assembly (8, Figure 3) is If a pilot sleeve and seal driver (or their equivalent) are not readily
assembled as follows: Ring Gear (27) must be riveted squarely and available, seal must be installed with a rubber hammer or block or wood to
firmly to output sleeve. Position ring gear on flange of output sleeve and prevent seal damage.
temporarily fasten with four cap screws and nuts. Position screws 90° CAUTION
apart and tighten in a crisscross sequence until gear is drawn down evenly. Damage to seals can be avoided by covering the shaft keyways with
Rivet the holes between the cap screws in a crisscross sequence. Remove cellophane tape, plastic shim stock or paper before sliding seals onto shaft.
cap screws and rivet remaining holes. Riveting force must be sufficient to REFILLING GEAR CASE WITH LUBRICANT
expand the rivet tightly in the holes and form a good rivet head.
Group 1, 2 and 3 Drives—Clean and recoat Drain Plug (1, Figures 3 and
NOTE: Model 790 ring gear is keyed to output sleeve. 4) with pipe sealant and replace in bottom of gear case. Remove Fill and
Place insertion tool and Bearing (24) on press anvil and press output Breather Plug (32, Figures 3 and 4) and Oil Level Plug (33,Figures 3 and 4).
sleeve into bearing. Reverse sleeve assembly and install Bearing (26). Fill gear case with recommended lubricant and follow all recommended
Assembly of Pinion Shaft Assembly (4, Figure 3) is essentially the reverse of procedures as detailed in Lubrication and Installation Instructions which are
the disassembly procedure. Use 1 gasket between Seal Carrier (11) and Pinion included with each Drive.
Housing (3). Bearing adjustment is similar to Group 1 Drives and Figures 8 and CAUTION
9 should be referred to. Do not install seals at this time. See FINAL
ASSEMBLY AND BACKLASH ADJUSTMENT section to complete assembly. Do not operate the unit without making sure it contains the correct amount
Group 3 Drives (not illustrated)—Assembly of cross shaft and pinion of lubricant. Do not overfill or underfill, or injury to personnel, unit, or other
assemblies is essentially the same as Group 1 Drives except a snap ring equipment may result.
holds the pinion shaft assembly together instead of a lock nut. No bearing CAUTION
adjustment is necessary on pinion shaft because ball bearings are self
Do not mix nonsynthetic and synthetic oil in the unit.
adjusting. Assembly of components in their proper order can be checked by
referring to the sectional view on the parts list sheet. Do not install seals at WARNING
this time. Make certain that all tools and other items are clear from rotating parts
FINAL ASSEMBLY & BACKLASH ADJUSTMENT before starting machine. Stand clear, and start machine slowly to be sure all
Group 1, 2 and 3 Drives—Install O-rings (17, Figures 3 and 4) into O-ring components are secure, and operating properly.

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 HUB CITY BEVEL GEAR DRIVES

Maintenance Instructions
DISASSEMBLY PROCEDURE GROUP 4 DRIVES 18
WARNING 19 14
Make certain that the power supply is disconnected before attempting to 11
service or install the unit, or remove any components. Lock out the power
5
supply, and tag it to prevent unexpected application of power.
Group 4 Drives (Refer to Figure 12 unless otherwise noted).
Field replacement of bevel gears, shafts, bearings, oil seals and O-rings
may be made on AD Series Bevel Gear Drives. If gear case, open or closed 15
caps or spacers need replacing it is recommended that the entire unit be 8
returned to the Hub City Factory for service. If this is inconvenient, the worn 13
or damaged spacer or cap may be sent to the factory so that it can be 9
precision duplicated. Each AD Series Drive contains caps and spacers 16
which are precision matched to the gear case. 17
Disassembly of Bevel Gear Drive is accomplished by removing Pinion 4
12
Assembly (4) from Gear Case (3) and draining (preferably while warm) all
lubricant from gear case.
WARNING
Wear protective clothing and eye shields when installing or maintaining unit
and machine.
Pinion Shaft Assembly (4) is removed from case by taking out Snap Ring
(5) and carefully sliding entire assembly out so that gear teeth are not
damaged and bearings are kept clean. Remove Snap Ring (6) on the
opposite gear side of case and carefully slide Output Shaft Assembly (7) out
of case. Remove Snap Ring. (8) from the gear side of case and slide out
Closed Cap (9) and remaining Ball Bearing (10). Note — all parts are
precision fit so no shims are necessary. Bearings should be removed 3
easily with only light pressure on the outer race. 10 23
IMPORTANT 22
All parts which are intended for reuse must be marked when they are 25
disassembled so that they are reassembled in their exact original position in 20
6
the case. If seals are to be reused, cover all shaft keyways with cellophane
tape, plastic shim stock or paper to avoid seal damage. 21
PINION SHAFT DISASSEMBLY
7
Slide Open Cap (11, Figure 12) and Outer Bearing (12) off Pinion Shaft (13).
Drive Spring Pin (14) out of Bevel Gear (15) and pinion shaft. Place pinion FIGURE 12 – Group 4 Drives 24
shaft in a press with shoulder of gear resting on the press anvil. Remove
gear by pushing shaft through gear. Remove Inner Ball Bearing (16) from FINAL ASSEMBLY
shaft. If pinion shaft is to be replaced and Spacer (17) salvaged, press off Group 4 Drives—Insert entire Output Shaft Assembly (7) into gear case
spacer carefully from shaft so that seal may be broken on Loctite® used to and secure Open Cap (25) with Snap Ring (6). Slide Remaining Ball Bearing
affix spacer to shaft. Remove Seal (18) from open cap with a driver tool or (10) over gear end of output shaft and tightly against Bevel Gear (22). Install
gently tap opposite sides of inner seal surface with a flat punch so that they Closed Cap (9) in gear case and secure with Snap Ring (8).
are removed evenly and no damage occurs to open cap counterbore. Fill gear case with the amount of Lubriplate 5555 recommended in chart
Remove O-ring (19) from open cap.
shown below.
OUTPUT SHAFT DISASSEMBLY Insert entire Pinion Shaft Assembly (4) into gear case, being careful to see
The disassembly of the Output Shaft Assembly (7, Figure 12) is essentially that bevel gears mesh. Secure with Snap ring (5).
the same as the procedure outlined above for the pinion shaft. No adjustment of bearings or gear backlash is necessary as all parts have
been precision fit. However, care should be taken that no foreign material is
ASSEMBLY PROCEDURE present between components during assembly that could alter the precision
Group 4 Drives—Clean and inspect all parts as detailed in Step 1 of spacing.
Assembly Procedure, Group 1, 2 and 3 Drives. LUBRICANT QUANTITIES
Align gears on shafts and secure with spring pins. Slide inner Ball
Bearing (16) tightly against bevel gear. Apply #602 Loctite® (or equivalent) MODEL QTY. REQ. MODEL QTY. REQ.
to spacer area of shaft and slide Spacer (17) on Pinion Shaft (13) and AD-1 & AD-2 & AD-5 1-1/2 oz.
against inner bearing. On Output Shaft Assembly (7), Spacer (20) is affixed AD-4 1/2 oz. AD-3 8 oz.
on Output Shaft (21) so that it is tight against Bevel Gear (22).
CAUTION
CAUTION
Do not overfill or underfill, or injury to personnel, unit, or other equipment
DO NOT GET LOCTITE® ON SEALS OR BEARINGS. may result.
Install O-rings into Caps (9, 11 and 25) and Seals (18 and 23) into open WARNING
caps with pilot sleeve and seal driver tools (see OIL SEAL INSTALLATION,
on previous page). Install Ball Bearing (24) on output shaft and Ball Bearing Make certain that all tools and other items are clear from rotating parts
(12) on pinion shaft. Slip pilot sleeve over keyway end of output shaft and before starting machine. Stand clear, and start machine slowly to be sure all
slide Open cap (25) down pilot sleeve until it is tightly against Bearing (24). components are secure and operating properly.
Slip pilot sleeve over keyway end of Pinion Shaft (13) and slide Open Cap For further information that may be helpful, see the Lubrication, Installation
(11) down pilot sleeve until it is tightly against Ball Bearing (12). Important— and illustrated Replacement Parts sheets for your Bevel Gear Drive. Should
If the pilot sleeve tool is not available, keyways must be covered with a particular problem arise or additional information be required, contact the
cellophane tape, plastic shim stock, etc., so that keyways do not damage nearest Hub City Sales Office, or Industrial Power Transmission Distributor
seals. which are listed in the Yellow Pages or contact Hub City — Aberdeen, SD.

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