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Old 05-05-2011, 08:51 AM   #1
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Gears, gears and more gears!

Hi Guys,

I have a class A here in Italy. The slide out stopped moving in and out so I pulled the Power Gear motor and broke open the gear box (if you want it fixed in Italy, do it yourself!) The gears fell out of the gear box and that's a problem, but first your input on a solution. The largest gear that drives the turning shaft is spinning freely on the shaft. The motor works fine, but with the gear turning and the shaft in the hub of the gear not moving, no movement of the slide. I noticed a small piece of metal the shape of a half moon in the bottom of the casing. I can tell that this is the locking mechanism for the gear to shaft, but even with a hammer I can't seem to get it into the groove in the shaft deep enough to make the gear stop spinning on the shaft. Do you think if I found a machine shop they would be able to press the tab into the shaft with high pressure? Any advice is appreciated....Eric in Italy
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Old 05-05-2011, 08:55 AM   #2
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Quote:
Originally Posted by EricB
Hi Guys,

I have a class A here in Italy. The slide out stopped moving in and out so I pulled the Power Gear motor and broke open the gear box (if you want it fixed in Italy, do it yourself!) The gears fell out of the gear box and that's a problem, but first your input on a solution. The largest gear that drives the turning shaft is spinning freely on the shaft. The motor works fine, but with the gear turning and the shaft in the hub of the gear not moving, no movement of the slide. I noticed a small piece of metal the shape of a half moon in the bottom of the casing. I can tell that this is the locking mechanism for the gear to shaft, but even with a hammer I can't seem to get it into the groove in the shaft deep enough to make the gear stop spinning on the shaft. Do you think if I found a machine shop they would be able to press the tab into the shaft with high pressure? Any advice is appreciated....Eric in Italy
Power gear responds quickly to emails. info@powergearus.com
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Old 05-05-2011, 09:27 AM   #3
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The half moon is called a key, and the groove is the keyway. There should be a keyway on both the gear and on the shaft.

The key should go into the keyway with relatively gentle tapping. Typically, especially if the gear is spinning on the shaft, there will be burrs at the top edges of the keyway that stop the key from going back in. Try to get a small file in there to clean up the top edges of the keyway without widening the sides. If there are nicks on the sides of key, file them off too. There also needs to be good alignment between the keyway on the shaft and the one on the gear before you try to get the key into the slot.
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Old 05-05-2011, 09:40 AM   #4
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There is a good posibility the top of the key was sheared off when the problem started. you will need a new key. Next check the keyway on both the shaft and the gear. If they are damaged , then a new key will just shear off. You may need to send pictures to the manufacture (or here) for evaluatuon.
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Old 05-05-2011, 09:42 AM   #5
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Thanks Guys....Tried Power gear by phone with no response, but e-mail came back quickly. All they can really offer me is a new motor and gear box, and they referred me to a retailer who only ships UPS and all I can get here at the Base is First class mail! Always a challenge serving our country from so far away! Paz- The detail of the key is rounded on one side and flat on the other with a small tab at the top of the flat part. Should that flat part go down into the keyway so it is not visable, or is it on top where it is visible. Also there is a half circle clamp and an o ring. Does the half circle clamp hold the key in place, and if so does the o-ring go over the half circle clamp? Details, details!
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Old 05-05-2011, 12:01 PM   #6
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My suggestion is to order the gear box. If the gears fell out when you opened it, you have more problems than a key.
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Old 05-05-2011, 12:27 PM   #7
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That Woodruff key is probably designed to shear if there is a problem so you don't burn up the motor or strip the gears. That half moon key is probably available here in the land of the big PX at most Ace Hardware stores or at Home Depot. They should slide in the groove easily and should not have to be hammered in. Before I would spend a lot of money on a gear box I would buy several of those keys new and give it a try.

It has been many years but if you drive from the base into Motta and when you get into Motta turn a sharp left and go down a hundred yards there should be a auto mechanic that speaks good English. I bet those keys are available in Sicily. There are several Ricambi (autoparts stores) around that should be able to match it. If not ask the guy that runs the auto hobby shop. They may have some or the Public Works garage. If not those guys at Public Works garage can sure tell you where to go to get some.

You can go to this link and match the size. When the page comes up scroll down
http://www.grainger.com/Grainger/wwg...N=0&sst=subset
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Old 05-05-2011, 05:08 PM   #8
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Quote:
Originally Posted by EricB View Post
Thanks Guys....Tried Power gear by phone with no response, but e-mail came back quickly. All they can really offer me is a new motor and gear box, and they referred me to a retailer who only ships UPS and all I can get here at the Base is First class mail! Always a challenge serving our country from so far away! Paz- The detail of the key is rounded on one side and flat on the other with a small tab at the top of the flat part. Should that flat part go down into the keyway so it is not visable, or is it on top where it is visible. Also there is a half circle clamp and an o ring. Does the half circle clamp hold the key in place, and if so does the o-ring go over the half circle clamp? Details, details!
You've got me stumped on all that. I've never seen the inside of the gearbox. It sounds like there is a lot more involved than a simple Woodruff key.

The Power Gear website has a lot of installation and service manuals. Some of them have a blow-up drawing of the assemblies. Maybe one of those will show the gearbox, which will help with your questions about how the parts go back together.

On the other hand, maybe the advice to bite the bullet and buy the whole gearbox is the way to go, unless you can find a way to just re-insert the key.
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