Honeywell DC3, DC2, DC6, DC4, DC5 manual Gearset Replacement

7.6Gearset Replacement

1.Apply PULSAlube grease # NP980006-000 to both sides of the thrust washer and install onto the eccentric shaft.

On the DC4, 5, and 6 models, the washer fits into a shallow counter-bore.

2.Assemble Worm Gear (Item 8) and key (Item 10) to the eccentric shaft. Do not tighten the setscrew yet.

3.Thread the M6-1.0 screw into the threaded hole in the end of the eccentric shaft. Tighten the Worm Gear set screw while simultaneously pulling on the screw in the end of the shaft in order to eliminate any endplay in the eccentric shaft.

4.Rotate the Worm Gear

It should turn easily with no perceptible endplay.

5.Remove the screw that was inserted in the shaft in step 3.

6.Assemble and install the worm shaft assembly

a)If you have a DC2 or 3 model:

Apply PULSAlube grease # NP980006-000 to the two lips of the worm shaft seal. Apply PULSAlube grease # NP980006-000 to the small end of the worm shaft. Carefully insert the worm shaft into the pump housing.

Assemble the lower thrust bearing (with a washer on each side) into the shallow counter bore in the bottom of the housing cavity.

Fit the shaft into the bearing in the housing.

b)If you have a DC4, 5, or 6 model:

Apply PULSAlube grease # NP980006-000 to the small end of the worm shaft.

Insert the worm shaft into the pump housing, fitting the end of the shaft into the bearing in the housing.

Apply PULSAlube grease # NP980006-000 to the two lips of the seal.

Assemble the adapter to the pump housing while carefully slipping the seal over the worm shaft.

7.Fill the gear cavity completely with PULSAlube grease # NP980006-000 and reassemble the pump side cover and gasket.

8.Reassemble the motor to the pump. Verify that motor rotation is clockwise when viewed from the top.

9.Reinstall the pump in the system and restart the pump (refer to Section 6 – Startup).

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