WORM GEAR ACTUATORS

SBWG SERIES

INSTALLATION AND
OPERATION MANUAL
FOR SBWG SERIES
WORM GEAR
ACTUATORS

Thank you for purchasing our SBWG Worm Gear Actuator. Before installing or operating actuator, please carefully read this
manual. The contents in this manual is subject to change due to quality improvement without individual notice.

www.challengervalves.com.au
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Index
This operating instruction can be applied for all worm gear models made by SAMBO Gears.
- Standard type : Gear actuators for general type
- Single reduction type (-1S type) : Horizontal input with single reduction gear attachment
- Double reduction type(-1SD type) : Horizontal input with double reduction gear attachment
- Triple reduction type(-2SD type) : Horizontal input with triple reduction gear attachment
- Declutch type : Use for emergency such as fire and explosion

1. SAFETY INSTRUCTIONS
1.1 Range of Application 3
1.2 Maintenance 3
1.3 Warning 3
2. TECHNICAL DATA 4
3. TRANSPORT, STORAGE & PACKING
3.1 Transport 6
3.2 Storage 6
3.3 Packing 6
4. FITTING HAND WHEEL & STEM BUSH
4.1 Hand wheel 6
4.2 Splined bushing 7
5. INPUT, OUTPUT SHAFT ROTATION OPTIONS
5.1 Right hand input 8
5.2 Left hand input 8
6. ADJUSTMENT OF SET SCREWS
6.1 Adjustment of set screws for 90° Rotation (Manual) 9
6.2 Adjustment of set screws for 90° Rotation (MOV) 9
7. ENCLOSURE PROTECTION IP-67, 68 10
8. MAINTENANCE
8.1 General Maintenance 11
8.2 Sealing 11
8.3 Grease 11
8.4 Removal & Replacement 11
9. SPARE PARTS LIST: STANDARD TYPE 12
10. SPARE PARTS LIST: SINGLE REDUCTION TYPE 14
11. SPARE PARTS LIST: DOUBLE REDUCTION TYPE 15
12. SERVICE 16
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SAFETY INSTRUCTIONS
1.1 Range of Application
Challenger Worm Gear Actuators are quarter-turn gearboxes intended to be used for the operation of valves (eg. Butterfly
Valves, Ball Valves, Damper etc.).

This gearbox is designed for not only manual operation but also motorised operation. If you need to use for other applications,
please contact sales@challengervalves.com.au.

Challenger are note responsible for any damage caused by incorrect use of the gearbox. The qualified personnel must be fully
aware of the instructions as described in this manual.

1.2 Maintenance
For safe operation of Worm Gearbox, please observe maintenance instructions (pg 12).

1.3 Warning
This manual contacts Warnings, marking activities or procedures which, if not carried out correctly, can affect the safety of
persons or material. Every caution should be taken to ensure all instructions contained herein are fully understood and
addressed during operation.

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TECHNICAL DATA

FEATURES AND FUNCTIONS

All external castings are Ductile Iron Class 65-45-12, Tensile Strength of 65,000PSI.
Housing
This provides high strength and excellent impact.

Indicators, "Close-Open-Close" are cast directly on the cover.

Housing Cover
This permits operation in either direction with position indication.

Standard material is Ductile Iron, Grade 80-55-06, suitable for most Industrial applications.
Normally required for motorised applications involving modulating service and is also a
Worm Gear
requirement to meet the AWWA standards.
The internal is splined to accept the splined bushing.

4140 Heat Treated Steel, with ground and polished worm threads.
Worm Precision cutting of the threads provides minimum backlash between the worm gear and
worm.
All units furnished with removable splined bushings to permit accurate position between the
Splined Bushings
gear drive and the valve shaft.

The drive sleeve is furnished with hardened steel thrust washers above and below worm
Thrust Washer
gear. This minimises frictional losses between the gear and the ductile iron castings.

Pointer provides positive position indication.

Indicator Plate
The pointer can easily be repositioned if required.
The worm is supported on tapered roller bearings which support both the axial and radial
Tapered Roller Bearing forces generated by the gearings.
They have excellent load bearing capacity.
Each end of the worm assembly is equipped with special design material (non-asbestos),
Gasket
which are completely water resistant.
External Adjustable Stops The stop bolts allow for position accuracy of +/- 5.

Units are available with single, double and triple reduction spur gears. This series of Worm
Output Torque
Gears range from 310Nm - 54000Nm.

The gearboxes are self-locking when at a stand-still under normal service conditions: strong
Self-locking vibrations may cancel the self-locking effect.
While in motion, safe braking is not guaranteed.

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TECHNICAL DATA (cont.)
WORM GEAR ACTUATORS FOR REDUCTION TYPE
Worm gear actuators for
reduction type
Mounting to valve
Spline bushing
Enclosure protection
Corrosion protection
Painting
Ambient temperature
Attachment on standard type and the reduction types are enabled to have various gear
ratios and direction to reduce the input torque.
VALVE ATTACHMENT
STANDARD: Manufacturing based on ISO 5211.
STANDARD: Supplied by Solid (blank) type or minimum pilot hole
OPTION: Supplied by One, two or four keyway etc.
SERVICE CONDITIONS
STANDARD: IP-67 (Perfect protection against dust and waterproof)
OPTION: IP-68 (To operate continuously in waterproof application contact Challenger
Valves and Actuators to confirm suitability).
STANDARD: Challenger gears are suitable for installation in industrial units in water or
power plants with a low pollutant concentration.
OPTION: Suitable for installation in extremely aggressive atmosphere with high humidity
and high pollutant concentration (Contact Challenger Valves and Actuators to confirm
suitability).
STANDARD: Jotun 412 Black
(Contact Challenger Valves and Actuators for special painting options)
STANDARD: -20°C to +120°C
OPTION: (Low temperature) -40°C to +90°C
(Extreme low temperature) -60°C to +90°C
(High temperature) -10°C to +200°C
(Contact Challenger Valves and Actuators for additional temperature options).
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TRANSPORT, STORAGE & PACKAGING

3.1 Transport
Transport to installation site in sturdy packaging. If mounted together with actuator, attach slings or hooks for the purpose of lifting by hoist
only to the gearbox and not to the actuator.

3.2 Storage
Challenger gears should be stored in a clean, dry area in their shipping containers. If stored for long periods of time, the actuator mounting
bases should be lightly greased to prevent corrosion.

3.3 Packaging
The gears are transported within protective packaging which consists of environmentally friendly materials for easy separation and
recycling.

FITTING THE HAND WHEEL

4.1 Hand wheel

For gearboxes designed for manual operation, the hand wheel is supplied separately. Fitting is done on site according to Figure 1.

Figure 1: Hand wheel

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FITTING THE HAND WHEEL (cont.)

4.2 Splined Bushing

All units furnished with removable splined bushings to permit accurate position between the gear drive and the valve shaft. Removal and
reassembly of the Splined Bushing is as follows:

Assembly

1.) Turn gearbox face down

POSITION INDICATOR
2.) Insert bush correctly into the worm gear
- Insert bush into groove of worm gear
- There are 2 grooves at bottom of worm gear
- One groove is for open and the other is for close
OPEN CLOSE
3.) Fix spring

Remove

1.) Remove fixed spring using suitable tool (flat head

screw driver)

2.) Remove splined bush

WORM GEAR

STEM BUSH

FIX SPRING

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INPUT, OUTPUT SHAFT ROTATION OPTIONS

5.1 Right Hand Input
RR(CW IN - CW OUT)
- Right hand input to clockwise (CW) rotation, output to clockwise (CW)
rotation. (CLOSE position)
- Standard type: Standard Flat Face. (Raised face available on request)

RL(CW IN - CCW OUT)

- Right hand input to clockwise (CW) rotation, output to counter clockwise
(CCW) rotation. (OPEN position)

5.2 Left Hand Input

LL (CW IN - CW OUT)
- Left hand input to clockwise (CW) rotation, output to clockwise (CW)
rotation. (CLOSE position)

LL (CW IN - CCW OUT)

- Left hand input to clockwise (CW) Rotation, output to counter clockwise
rotation. (OPEN Position)

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ADJUSTMENT OF SET SCREWS

6.1 Adjustment of set screws for 90° Rotation (manual hand wheel type)

- Manoeuvre valve and actuator to closed

position.
- Adjust the closed set screw on the
gearbox, repeat for the open position

6.2 Adjustment of set screws for 90° Rotation (MOV type)

- Manoeuvre valve and actuator to closed

position.
- Adjust the closed set screw on the
gearbox, repeat for the open position

WARNING: Set screws are set in the warehouse prior to delivery, if settings are altered the user is responsible for any
damage that may occur.

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ENCLOSURE PROTECTION IP-67, 68

Definition:
IP67: According to IEC 529, the conditions for meeting the requirements of enclosure protection IP67. Under the
conditions for regular pressure and time, test regulation can meet to prevent ingress of water. (15cm-1m)

Contents:
- Challenger worm gearboxes in enclosure protection IP 67 fulfil the following requirements in compliance with
Challenger definitions.
- IP67: Complete enclosure protection for dust and no ingress of water during submersion. (Standard)
- IP68: Complete enclosure protection for dust and suitable to use continuously during submersion.
- Test regulation is to be agreed between manufacturer and user. (OPTION)
- If submersed in other media, additional measures for corrosion protection may be necessary.
(Please contact Challenger Valves and Actuators)

Note:
The enclosure protection IP 67 is available to the interior of the gearbox, but does not protect mounting flange. If
gearboxes are likely to be repeatedly submersed, a higher corrosion protection may be necessary (Please contact
Challenger Valves and Actuators).

- Use suitable sealing material between valve flange and gearbox.

- If unsuitable sealing material is used, water can not be prevented from entering the coupling via the mounting
flange part, this leads to corrosion within the interior of the gearbox.
- To protect from this type of corrosion, we would suggest you select higher corrosion protection before
mounting valve.

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MAINTENANCE

8.1 General Maintenance

- Check the external appearance for foreign matter and clean if required.
- If coating is damaged this may lead to corrosion or rust, re-coat if necessary.
- The gearbox is required to operate at least 10 times per year
- Check the following points:
- Every 6-12 months check worm gear actuators for cleanliness and general condition.
- Valve must operate 5 times per 6 months.
- Check for grease leakage every 12 months. (Fill up grease if required)

8.2 Sealing
- Life cycle of NBR seals is about 12 years from manufacturing date. (The life cycle is based on average 40°C)

8.3 Grease
- Change grease as per below:
- In case of operating rarely: 10 to 12 years
- In case of operating normally: 6 to 8 years
- In case of operating frequently: 4 to 6 years

- Contact Challenger Valves and Actuators for grease specification.

- Do not mix lubricant with any other fluids.
- When removing lubricant and cleaning inside gear actuators, observe the correct instruction of replacement & remove
(see 8.4)
- Challenger is not responsible for any damage caused by incorrect removal and replacement.

8.4 Removal & Replacement

- Challenger worm gears have a long life cycle, but proper replacement should be required to maintain this long life
cycle.
- Challenger is not responsible for any damage caused by incorrect removal, assembly or replacement.

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SPARE PARTS LIST: STANDARD TYPE

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SPARE PARTS LIST: STANDARD TYPE (cont.)

Material
No. Description Remark
Name ASTM

01 Housing Ductile Iron A536-65-45-12 Note 1

02 Cover Ductile Iron A536-65-45-12

03 Worm Alloy Steel A322-4140 Note 2

04 Stem Nut Ductile Iron 65-45-12

05 Worm Wheel Ductile Iron 80-55-06 B1486-C-95800 (ALBC3)

06 Front Cap Carbon Steel A576-1045

07 End Cap Carbon Steel A576-1045

08 Indicator Plate Carbon Steel A576-1020

09 Thrust Washer Carbon Steel A283 GR.D

10 Fixed Spring Special Steel AISI 1075

11 Taper Roll Bearing Special Steel A295-52100

12 Hex Bolt (S/W) Alloy Steel A322-4140

13 Hex Bolt (S/W) Alloy Steel A322-4140

14 Hex Bolt (P/W) Alloy Steel A322-4140

15 Hex Bolt Alloy Steel A322-4140

16 Hex Nut Alloy Steel A322-4140

17 O-Ring Buna N NBR

18 O-Ring Buna N NBR

Note 3
19 O-Ring Buna N NBR

20 O-Ring Buna N NBR

21 Cover Gasket NON-Asbestos

VALQUA 6500
22 Cap Gasket NON-Asbestos

23 Packing Seal Buna N NBR

24 Grease Fitting Carbon Steel A576-1020

25 Eye Bolt Carbon Steel A576-1020

OP-1 Hand Wheel Steel Pipe A53

OP-2 Key (1R) Carbon Steel A576-1045

OP-3 Name Plate Aluminium Handle Part

Note 4
OP-4 Washer Carbon Steel A283 GR.D

OP-5 Hex. Bolt (S/W) Alloy Steel A276-304

Material details: Options and Material changes

1. All castings are Ductile Iron, FCD-450 (ASTM Class 65-45-12)
2. Option for Nickel coating, high tensile stainless.
3. O-Ring Seals and Lubricant:
- Standards is Buna “N”, temperature range –30°C to +120°C
- Standard lubricant is Shell Alvania EP2, Temperature range –20°C to 120°C
Other Options:
High Temperature
Viton O-Ring Grade V75, Temperature range –25°C to +200°C
Lubricant—Shell Darina R2, Temperature range –10°C to +200°C
Low Temperature
Viton O-Ring Grade V115, Temperature range –35°C to +160°C
Lubricant—Shell S-6751, Temperature range –40°C to +90°C
4. We offer a wide variety of Hand Wheels, Chain Wheels, Input Shaft Locking Devices, etc.
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SPARE PARTS LIST: SINGLE REDUCTION TYPE

Material
No. Description Remark
Name ASTM

01 Housing Ductile Iron A536-65-45-12

02 Cover Ductile Iron A536-65-45-12

03 Worm Alloy Steel A322-4140

04 Stem Nut Ductile Iron A536-65-45-12

Material
05 Worm Wheel Ductile Iron A536-80-55-06 ALBC3 No. Description Remark
Name ASTM
06 Front Cap Carbon Steel A576-1045
SU-1 Support Housing Ductile Iron A536-65-45-12
07 End Cap Carbon Steel A576-1045
SU-2 Helical Pinion Alloy Steel A322-4140
08 Indicator Plate Carbon Steel A576-1020
SU-3 Radial Ball B/R Special Steel A295-52100
09 Thrust Washer Carbon Steel A283 GR.D
SU-4 Radial Ball B/R Special Steel A295-52100
10 Fixed Spring Special Steel AISI 1075
SU-5 Idle Gear Alloy Steel A322-4140
11 Taper Roll Bearing Special Steel A295-52100
SU-6 Radial Ball B/R Special Steel A295-52100
12 Hex Bolt (S/P) Alloy Steel A322-4140
SU-7 Helical Gear Alloy Steel A322-4140
13 Hex Bolt (S/P) Alloy Steel A322-4140
SU-8 Key (1R) Carbon Steel W1-8
14 Hex Bolt (S/P) Alloy Steel A322-4140
SU-9 Snap Ring Carbon Steel A576-1045
15 Hex Bolt Alloy Steel A322-4140
SU-10 Radial Ball B/R Special Steel A295-52100
16 Hex Nut Alloy Steel A322-4140
SU-11 Support Cover Ductile Iron A536-65-45-12
17 O-Ring Buna N NBR
SU-12 S-Cover Gasket NON-Asbestos VALQUA 6500
18 O-Ring Buna N NBR
SU-13 Hex Bolt (S/W) Alloy Steel A322-4140
19 O-Ring Buna N NBR
SU-14 Retainer Buna-N NBR
20 Retainer Buna N NBR

21 Cover Gasket NON-Asbestos OP-1 Hand Wheel Steel Pipe A53

VALQUA 6500
22 End Cap Gasket NON-Asbestos OP-2 Key (1R) Carbon Steel A576-1045
Option
23 Packing Seal Buna N NBR OP-3 Name Plate Aluminium
Handle Part
24 Grease Fitting Carbon Steel A576-1020 OP-4 Washer Carbon Steel A283 GR.D

25 Eye Bolt Carbon Steel A576-1020 OP-5 Hex Bolt (S/W) Alloy Steel A276-304

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SPARE PARTS LIST: DOUBLE REDUCTION TYPE

Material
No. Description Remark
Name ASTM

01 Housing Ductile Iron A536-65-45-12

02 Cover Ductile Iron A536-65-45-12

03 Worm Alloy Steel A322-4140

04 Stem Nut Ductile Iron A536-65-45-12

Material
05 Worm Wheel Ductile Iron A536-80-55-06 ALBC3 No. Description Remark
Name ASTM
06 Front Cap Carbon Steel A576-1045
SU-1 Support Housing Ductile Iron A536-65-45-12
07 End Cap Carbon Steel A576-1045
SU-2 Helical Pinion Alloy Steel A322-4140
08 Indicator Plate Carbon Steel A576-1020
SU-3 Radial Ball B/R Special Steel A295-52100
09 Thrust Washer Carbon Steel A283 GR.D
SU-4 Radial Ball B/R Special Steel A295-52100
10 Fixed Spring Special Steel AISI 1075
SU-5 Idle Gear Alloy Steel A322-4140
11 Taper Roll Bearing Special Steel A295-52100
SU-6 Radial Ball B/R Special Steel A295-52100
12 Hex Bolt (S/P) Alloy Steel A322-4140
SU-7 Helical Gear Alloy Steel A322-4140
13 Hex Bolt (S/P) Alloy Steel A322-4140
SU-8 Key (1R) Carbon Steel A576-1045
14 Hex Bolt (S/P) Alloy Steel A322-4140
SU-9 Snap Ring Carbon Steel A576-1045
15 Hex Bolt Alloy Steel A322-4140
SU-10 Radial Ball B/R Special Steel A295-52100
16 Hex Nut Alloy Steel A322-4140
SU-11 Support Cover Ductile Iron A536-65-45-12
17 O-Ring Buna N NBR
SU-12 S-Cover Gasket NON-Asbestos VALQUA 6500
18 O-Ring Buna N NBR
SU-13 Hex Bolt (S/W) Alloy Steel A322-4140
19 O-Ring Buna N NBR
SU-14 Retainer Buna-N NBR
20 Retainer Buna N NBR

21 Cover Gasket NON-Asbestos OP-1 Hand Wheel Steel Pipe A53

VALQUA 6500
22 End Cap Gasket NON-Asbestos OP-2 Key (1R) Carbon Steel A576-1045
Option
23 Packing Seal Buna N NBR OP-3 Name Plate Aluminium
Handle Part
24 Grease Fitting Carbon Steel A576-1020 OP-4 Washer Carbon Steel A283 GR.D

25 Eye Bolt Carbon Steel A576-1020 OP-5 Hex Bolt (S/W) Alloy Steel A276-304
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SERVICE

Horizontal Type

Flange
(for electric actuator) Locking Device

Vertical Type

Flange
(for electric actuator) Square Adaptor Underground

Special Type

Travelling Nut Stop Declutch Gear Planet Reduction Air Cylinder

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