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MCR5 Rexroth Wheel Motor

MCR5 Rexroth Wheel Motor

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RE 15205 R to RE 15210 R 06.

00

RE 15205 R to RE 15210 R 06.00

MCR Motors Service Manual Series 32 Low Speed High Torque Motor MCR3, 5, 10, 15, 20 & 40 AOM, B-M, C-M Two Speed Displacement 160 to 4200 cc/rev

MCR5C ... F180Z -32/B4M/../S

1/20

RE 15205 R to RE 15210 R 06.00

Series 32 Service Manual

Notice:

Designations, descriptions and presentations correspond to the state of information at the date of impression of this manual. Modifications may influence the product service without any obligations for us arising there from. Methods and set-ups are recommendations only, no liability is undertaken by Rexroth for the results.

Page
Safety Instructions ................................................................................................................................................. 3 Installation ............................................................................................................................................................. 3 Commissioning ...................................................................................................................................................... 4 Operation .............................................................................................................................................................. 4 Mechanical brake release ...................................................................................................................................... 4 1. Dismantling Instructions ................................................................................................................................ 5 1.0 1.1 1.2 1.3 1.4 1.5 1.6 Park brake disassembly (B-M) ..................................................................................................................... 5 Drum brake shoe inspection and removal (C-M)........................................................................................... 6 Motor disassembly ...................................................................................................................................... 6 Drum brake/Front casing disassembly ('F' type with C-M) ............................................................................. 6 Front casing disassembly (All types) ............................................................................................................ 7 Rear casing disassembly ............................................................................................................................. 8 Rotating group disassembly ........................................................................................................................ 9

2. Reassembly Instructions .............................................................................................................................. 10 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Front casing assembly (All types) .............................................................................................................. 10 Drum/Dynamic brake assembly ................................................................................................................. 12 Dynamic brake/Front casing assembly/setting ('F' type with C-M) ............................................................... 13 Rotating group assembly ........................................................................................................................... 14 Rear casing assembly ............................................................................................................................... 15 Motor assembly ........................................................................................................................................ 17 Park brake assembly (B-M) ....................................................................................................................... 17 Park brake test (B-M) ................................................................................................................................ 18

3. Options ......................................................................................................................................................... 19 3.1 3.2 Flushing valve disassembly ....................................................................................................................... 19 Flushing valve assembly ........................................................................................................................... 19

Appendices:

Page

A. Tooling ............................................................................................................................................................ 20 B. Grease specification ........................................................................................................................................ 20 C. Fault finding .................................................................................................................................................... 20

Rexroth Hydraulics

2/20

Ensure all packing/shipping plugs are removed prior to use. For acceptability of other fluids please refer to authorized Rexroth agent. allowing no distortion of motor mounting flange. (HTG.e. temperature changes of system. Oil contamination must not exceed NAS 1638 class 9 (or SAE class 6. therefore well maintained filtration is essential. f. If in doubt consult authorised Rexroth agent. All shipping plugs shall be removed prior to connection of hydraulic lines to motor. i. Brake shoes on new drum brake assemblies should be run in by driving with the brakes partially on for a period of 2 minutes. Shaft connection to mechanical drive must use all mounting holes specified on output shaft. HPG. speeds. 3/20 Rexroth Hydraulics . Pressure at leakage port must not exceed 10 bar. a. It is prerequisite that work is carried out only by qualified personnel. Note : Motors are tested with mineral oil and system must be fully flushed prior to use of any alternative fluid type.Series 32 Service Manual RE 15205 R to RE 15210 R 06. A suitable flexible coupling should be used if this loading cannot be avoided. Ensure leakage port pressure does not exceed 10 bar. d. Hydraulic line should be sized accordingly. c. Recommended minimum bore of hydraulic lines is 8mm. g. b. Connections shall be sized to minimise pressure losses. Motor output shaft rotates on supply of pressure to the motor. All connections must be completed prior to motor operation. Prior to operation the motor will be securely mounted using all the motor mounting holes with an arrangement capable of with standing maximum torque and all external loads placed on motor shaft. If in doubt contact an authorised Rexroth agent. The required level of cleanliness may normally be achieved by filters with a minimum retention rate of b10³75. e. General The following repair instructions are intended to assist in inspections and repairs to be carried out. Leakage port should be mounted near the top to ensure motor is permanently oil filled. d. Maximum pressures. Hydraulic fluid used is mineral oil (HL. Environmentally acceptable hydraulic fluid. f. HE to RE90221) are acceptable subject to reduced guarantee. Operational limits for full functionality are 16mm2/s < a < 100mm2/s with optimum results obtained at 16mm2/s < a < 36mm2/s. whichever is the shortest. Installation a. e. Motors contain stored energy in the form of compressed springs and this must be released using the method specified in the disassembly instructions.00 Safety Instructions Warning: Damage or injury may result if any of the instructions in this manual are not followed. Care must be taken to ensure no loading is generated by eccentric mounting of motor to a load. etc. b. Connection lines are to be designed such as to impose minimum loading on motor due to vibration. These units are manufactured with great care and with adherence to defined tolerances to the highest manufacturing accuracy. The maximum permissible interval between system oil changes is every 2. Motors shall be fully supported as specified in installation instructions prior to application of pressure. and shaft loads applied to motor shall not exceed relevant data sheet limits. c. When lifting motors use slings/shackles rated for motor weight. movement. Ensure mounting face is flat and perpendicular to motor axis. Oil cleanliness is vital to obtaining long service life. g. ISO / DIN 4406 class 18/15). Prior to attempting any maintenance work on motor ensure all pressure sources have been disconnected. Viscosity should be greater than 10mm2/s and less than 2000mm2/s under all conditions. Motor connections should be accordance with relevant international standards and rated for maximum system pressure. using the maximum motor leakage flow in the relevant data sheet. Typically a 10 micron filter. Care should be taken in placement of filters in the system and consequent pressure drops across filters. HLP) to DIN 51524. Alternatively a check valve may be placed in drain line to ensure motor is permanently oil filled.000 hours running time or yearly.

340Nm Approx. e. Hand tighten screw to brake piston. flushing may be added to obtain temperature reduction. washer. Check motor is free from leaks. Confirm unit is oil tight. charge pressure and power are within current datasheet recommendations. 15. fitted with special tool 12. b. Turn screw until brake is released (Approx 1 turn).Case drain pressure is <10 bar (145 psi). 230Nm Approx. as per table 1 shown below. b. . Periodically check motor is still securely mounted and running at normal temperature. Under operating conditions confirm: . Table 1 Motor Type MCR3 MCR5 MCR10 MCR15 MCR20 Screw Size M12 M16 M16 M20 M20 Screw Length 30mm 30mm 40mm 45mm 50mm Torque 60Nm Approx. Position a screw. Storage. 160Nm Approx. check brake functions. .2 speed switching pressure is >15 bar (210 psi) over case pressure and <30 bar (435 psi). c. 20 & 40 motors a bar. Mechanical brake release See Fig. into item 67. item 73. sound level and leakage. d.Fill with hydraulic fluid. For up to 36 months :. If in doubt consult authorised Rexroth agent. pressures.Operating speeds. item 67.00 Series 32 Service Manual Motor Rotation Standard Design All Single Speed & Two Speed Code 2W Switchable (Preferred Rotation) Two speed Code 2L or 2R B A B A B A Motor code "2L" Slot "L" on Distributor Motor code "2R" Slot "R" on Distributor Viewed on Shaft End Commissioning a. Rexroth Hydraulics 4/20 Remove screwed cap. item 72.RE 15205 R to RE 15210 R 06.Park brake pressure is >15 bar (210 psi) and <30 bar (435 psi). special tool 13. (on MCR10. 1. d. . Ensure mechanical release is disengaged after use to maintain fail-safe operation of brake. If braked motor. . For extreme load or speed conditions. Important : Mechanical brake release should only be used in the event of hydraulic failure. Monitor oil cleanliness at regular intervals. For operations above this temperature please consult Rexroth. Ensure system is completely flushed to rated oil cleanliness levels prior to commissioning.Case drain oil leakage temperature <80°C (176°F). Warning : During the running in period (minimum 24 hours) the motor should not be run unloaded at greater than 50% of maximum speed. . Operation a. is to used instead of the tool 12) through the centre of end plate. Package if in open air. Flush using both motor drain ports L and F. . Page 6. c.Charge pressure of >15 bar (210 psi) is recommended. 120Nm Approx.

one turn at a time. 1.C. Remove external dirt. item 26.H. 1. item 70. items 77 & 78. 1.5 Remove piston. 1. 1. f. . item 92. heavy abrasion. Figure 1. item 65. Discolouration of components with heavy loading. 1. Dismantling a. Carry out step by step dismantling. Have ready a clean work place.0. item 5..0. h.S.6 Remove piston seal. If friction 1. lay out tools ready.0.1. item 88 and all washers.1 Fully release dynamic brake. (Socket Head Cap Screw).00 Important : Always refer to relevant assembly drawing.8 The brake housing. item 67. shims. 5/20 Rexroth Hydraulics . clean off the rust at its joints and apply a small amount of penetrating fluid. relative to rear case. item 94. .0. d. For example :Scored sliding surfaces. 1.4 Remove cover plate.7 Remove all S. unless damaged in which case it should be replaced. 80 and brake shaft. from brake housing.0 Park Brake Dismantling Instructions (B-M only) See figure 1.1. Unscrew alternately. item 89. using tapped hole.1. disc spring. b. item 65. 1.C.0.4 Check the thickness of the brake shoe friction lining. immediately close openings with plugs to prevent ingress of contamination. grease and all old Loctite.S.0.0. When dismantling the unit from the machine.H.contaminated operating fluid. items 79. type number and running time of unit (for ordering spare parts). e.3 Remove all S. item 66. item 100. (C-M motors only) See figures 2 & 3.3 Remove brake drum. 1. item 66 can now be removed. gasket.Series 32 Service Manual RE 15205 R to RE 15210 R 06. Make note of the details on code plate such as serial number. brake discs. Prior to applying Loctite to a part ensure it and its mating part are clean.2 Drain oil from the motor by removing drainage plug. 1. B-M Park Brake.9 Remove seal. item 90. . Use only non-threading cleaning cloths. If it is tight. Take care to avoid oil on brake shoes. from piston.1 Mark rotational position of brake housing. item 67.0.2 Plug brake port.0. free from oil. item 74.0. item 65. c. item 72.overheating of operating fluid. should remain fixed to shaft. g. item 82. 1.insufficient oil. The appearance of the parts removed often gives an indication of the condition of the system. 1. 1.1. 1. 1.1 Drum Brake shoe inspection and removal. incorrect choice of viscosity or inadequate specification of operating fluid.10 Bush.

item 4.2 Remove split ring.3. 1. out of bearings. the brake cable position relative to the motor and the holes fixing the retaining springs.1.3.06in) or less. 1. of item 7.4 Remove rear case assembly.6 Lift dynamic brake from front case assembly. item 22.3 Support front casing on blocks and press shaft.5 Remove all S. item 7.11 If fitted.5mm (0.1 Remove O-ring. item 11 (and 14 if fitted).2.3. item 12. item 1. 1. items 26 to 60 and rotational assemblies items 18 to 25.2.H. 1.3.3. item B (2 off). Front Case ‘F’ Type with C-M Brake C D x2 B x2 A x2 E F x2 lining thickness is 1. Note how cable hooks onto dynamic brake.RE 15205 R to RE 15210 R 06. from front case using a mechanical puller or a soft steel drift. using cam. item 2. item 3.3. 1. Rexroth Hydraulics 6/20 .3. Remove rear bearing cone.2.1. 1. item 1. remove spacer.2 If not previously done. 1.2. item E.1. Part section Drum Brake fixing screws. For motors fitted with piston springs (motor codes containing XM) take care to hold pistons. in cylinder block. item F (2 off). from front case. from front case using a mechanical puller or a soft steel drift. 1. 1. item 1. item 100 and drain oil from motor. 1.5 Note the position of the shoes. 1.3 Remove all capscrews.3. item A (2 off).8 Remove bolts. item 10. item 25.3. Allowing plate. using a mechanical puller. using a soft steel drift to separate. are glazed then roughen surface with emery paper.1. and unhook from back plate.10 Remove bearing cone. the shoe must be renewed. 1.1 Mark the relative rotational positions of the front case.1. 1. 1.2 Motor Dismantling Instruction See figure 1 on page 5. 1. 1. from the shaft.7 Lever lip seal.9 Remove front bearing cup.8 Remove rear bearing cup. 1.11 Remove brake shoes. item D (2off).9 Remove retaining springs.6 Remove brake cable. to be removed.1. item 63.12 If brake shoes. from front case. remove plug. item 53.1. from shaft. item 20.00 Series 32 Service Manual Figure 2. 1.3. item 41.S.10 Remove retaining spring. 1.1.7 Depress retaining springs. 1.3 Dismantling Front Casing Motor type F with Drum brake(C-M motor only) See figures 2 & 3.4 Remove wiper seal. 1. from assembly. item 6. 1.3. 1. 1. rear case and rotational assemblies. item C. 1. of item 6. Then remove washer.C. Dynamic Brake C-M Figure 3. item F.

Figure 4. and/or front case.1 1.4.4 1. from shaft. MCR10. Carefully remove seal.4. ‘F’ & ‘G’ Type Remove O-ring.5 1. remove shaft spacer. Remove bearing cup. using a mechanical puller or soft steel drift.4 1. item 1. Remove rear bearing cup. ‘D’ & ‘E’ Type Figure 6. Remove split ring.4.4. item 3. 20 & 40 Front Case ‘C’ & ‘F’ Type Figure 7.3 1.4. If fitted. from the shaft.4.Series 32 Service Manual RE 15205 R to RE 15210 R 06. of item 6. from shaft. item 10. Remove rear bearing cone. item 11.4. MCR3 & 5 Front Case ‘A’. Then remove washer. Carefully remove seal.00 1. item 12.8 1.7 1.6 1. MCR3 & 5 Front Case ‘C’. item 1. from rear case using a mechanical puller or soft steel drift. items 6 & 7. from front case. Figure 5. item 1. from assembly.4. Remove bearing cones. using mechanical puller.4. 15.9 Dismantling Front Casing. out of bearings. item 2. using a soft steel drift to separate. item 41. item 2.2 1. all Types See figures 4. item 4. of item 7. 5. item 7. item 1. Support front casing on blocks and press shaft. 6 & 7. MCR10 Front Case ‘D’ Type 7/20 Rexroth Hydraulics .

If necessary lap timing face. 1.5. item 28. A0M.5. 9 & 10.5.1 A_M & C_M Motors only. Two Speed MCR10 & 15 Low Displacement. A0M.6 Check timing face of distributor. 41 (and 36 if fitted).4 Drop the rear case assembly from approximately 80mm onto a wooden or plastic surface (timing face down). Single & Two Speed Rexroth Hydraulics 8/20 . item 38. item 26. 1. item 26.2 A_M & C_M Motors only. 1. MCR20 & 40 Low Displacement. item 26. A0M.5.5 Dismantling the Rear Casing Assembly See figures 8. A0M. 1. Single Speed Figure 10.7 Remove and discard all the seal rings if fitted. item 27. from assembly.5. from rear case. 1.3 Remove O-rings.00 Series 32 Service Manual 1.5. 1. items 47 to 51.5. Single & Two Speed Figure 8. Remove end cover. Remove all hex head screws. item 31. MCR3 & 5 Low Displacement. Figure 9.RE 15205 R to RE 15210 R 06. from rear case. This will release distributor. 1. item 39. MCR3 & 5 Low Displacement. from rear case. At all times take care not to damage timing face.5 Remove stop pin.

8 Remove spool valve assembly. 1.6. items 55. (2 off). cloths should be held firmly over the entire rotating group when Figure 12b. from spool valve assembly. from piston assembly and check for wear on rollers piston seats.2 Remove cam. Alternative design. 1. Code "2W" Two Speed Spool Valve 1. 1.5. Remove internal spool and spring. item 60.1 Piston spring motors only (motor codes containing XM). remove circlip.5.6. Figure 14. Code "2L/2R" Two Speed Spool Valve Figure 13. item 23. 22 and the springs. from cover or brake housing. from spool valve. 1.7 Check timing face of cylinder block. and washer. 58 and Code 2W only items 71 & 76. 1. can be removed under gravity or by low air pressure applied to the ports in the cylinder block. item 56. 1. item 18.14 Inspect spool for damage. item 21 & 22. 56.11 Remove circlip. High displacement motors only. All motors 1. replace if required. at the edges with blocks.5. If necessary lap timing face. 1.6. becoming damaged or lost. item 58.3 Supporting cylinder block. item 59.6.5 Each piston assembly. High Displacement 9/20 Rexroth Hydraulics .6. items 21.5.6. Code "2W" removing cam. Figure 11.5.Series 32 Service Manual RE 15205 R to RE 15210 R 06. and seal.6 Remove rollers. item 20. Two Speed Spool Valve. from cover or brake housing.10 Remove spring. from rotational assembly. Low Displacement 1. To prevent piston assemblies. Remove seal ring. item 24 (2 off). 1.5.6 Dismantling Rotating Assembly See figures 13 & 14.12 2W figure 12 only.00 Two Speed Motors Only See figures 11.4 Remove retaining rings. item 25. 1. care should be taken when dismantling the piston assemblies. item 20. item 54. item 21. item 25. item 71. 1.6. Figure 12.5. If optional springs fitted.9 2W figure 12 only. 1.13 Remove seal. item 57. item 55. 12 & 12b. 1.

2. co-ordinated and tested component groups. Place spacer item 12. All Types (except C-M motors. item 10. MCR3 & 5 Front Case ‘C’. with G3 grease. c.8 Place drive shaft.1. into front case.1 Ensure all components are clean and free from debris.10 Warm front bearing cone. using special assembly tool 1.1. to front case. into front case. If in doubt contact the local authorised Rexroth agent. Smear lip of seal with G3 grease. vertically on a press. Should difficulties arise.1. 20. place suitable sized cylinder underneath shaft flange. please contact your nearest service centre. item 2. then press onto shaft. using special assembly tool 5. and shaft. item 11.) See figures 15. item 2. 2. Fit seal. onto shaft.1. 2.11 MCR3. 2. Do not re-use old seals. with G3 grease. item 6. f. item 7.RE 15205 R to RE 15210 R 06. b. item 1.2 Insert bearing cup. ‘D’ & ‘E’ Type 2. 2. 16. items 53.6 MCR10. 2. item 1.9 If required. item 1. to shaft. 2. to protect lip seal.1. item 1. 2. Rexroth Hydraulics 10/20 . Smear contact faces with system oil.1. MCR20 & 40 Only. 5 and MCR10 ‘D’ Type only.1 Reassembling Front Casing.1. 40 ‘C’ & ‘F’ Only.5 MCR3 & 5 only. 2. On completion of repair. 17 & 18.1.00 Series 32 Service Manual Figure 15.13 Fit front case assembly to shaft assembly. We recommend the use of pre-assembled. e. are changed at reassembly. into front case. 88 and 90. item 6. 15. ‘F’ & ‘G’ Type Reassembly a. 2. item 2. Tighten screws with torque wrench according to specification. 5 & MCR10 ‘D’ Only. We recommend that all fastening screws. using special assembly tool 4. The required component groups and seal kits should be selected from the spares list and ordered by quoting the name plate details.4 Insert rear bearing cup. 2.1.1. item 10. Assembly should be carried out observing the maximum cleanliness.12 Cover shaft spline diameter with tape. Insert seal item 11. 2. close all openings with plugs. Fit both halves of seal. Smear lip of seal. (Cylinder should be large enough to ensure shaft rests on cylinder not wheel studs). MCR3 & 5 Front Case ‘A’.1. item 1. item 6. using special assembly tool 3.7 MCR5 ‘F’. item 2.3 MCR3.1. Oil all seal contact areas before assembly using system hydraulic oil unless otherwise stated in text. using bench press and special assembly tool 2. Figure 16. item 1. Use only genuine Rexroth Spare Parts. d.1. 2. Pack front bearing cone.

Insert seal. item 2. prior to assembly. item 11.24 Place aside and cover to protect against ingress of dirt. item 1. rotates in front casing assembly.15 Remove tape from spline. item 4.1. and insert in drive shaft. 15.22 MCR10. Half fill volume with system oil.1. with thickness 0. then refit split ring.Series 32 Service Manual RE 15205 R to RE 15210 R 06. apply Loctite 542 to plug. 2. 11/20 Rexroth Hydraulics . item 1. Fit Seal. item 17. apply a load of 4 tonne to rear bearing. 2. 2.1. Ensure hole for plug. 15. then refit split ring.004" to 0. item 3.1.17 Using bench press and special assembly tool 7.22 Check shaft. item 7 and fit split ring. 20 & 40 'C' and 'F' Only. 20 & 40 ‘C’ and ‘F’ Only. Figure 18.1 to 0. into front case. onto shaft.00 Figure 17.008" to 0. item 11. Remove split ring. 2. 2.16 Warm rear bearing cone.2 to 0. by pressing onto shaft using bench press and special assembly tool 6 to a load of 4 tonnes. 20 & 40 only. Rotate case during this process. Remove split ring.1. 20 & 40 Front Case ‘C’ & ‘F’ Type 2. MCR10. and fit a washer. Smear lip of seal.23 MCR10 ‘D’ Type Only.1.18 With pre-load still applied. MCR10 Front Case ‘D’ Type 2.012") greater than measured gap. item 17.14 MCR10. item 2. Smear lip of seal with G3 grease. item 10.1.19 Remove load. 2. and fit a washer. item 4. with G3 grease. and fit to shaft. 15. measure gap between bearing and split ring with slip gauges (This step should be completed less than 10 minutes after removing bearing from heater).21 MCR10. 2.008") greater than measured gap. with thickness 0.1. into front case.2mm (0. item 7. Rotate the front case 5 times during this process. 2. item 11.1.1. 2. is ventilated during assembly of seal.1. 15. item 1. using special tool 4.3mm (0. item 3. 2. item 4.20 MCR3 & 5 only. item 1.1.

so allowing brake drum to be fitted. item C.2. Dynamic Brake C-M C B D x2 x2 2. using special assembly tool 4.2.6 With pliers fit lower retaining spring.10 Fit brake cable. 2. 2.2 Insert bearing cup.2.8 MCR3 and 10 only. using special assembly tool 5.3.6 Insert rear bearing cup. (Use brake and clutch cleaner). 2.2. Insert socket head capscrew. Align bolt holes. 2. 2. Firgure 19.7 With pliers fit upper retaining springs. 2. This decrease's brake shoe O. item 2.2. item E. item 7. 2.9 Torque screws.7 Lift dynamic brake.1 Fit plate. Fit washers.3.5 With a soft mallet tap shoes inward. item 2. item 2. 2. item D (2 off). items 11 & 14. into front case.3. 2.1 Ensure all components are clean and free from debris. 2. with lip seal.2 Reassembling Dynamic Brake (C-M motors only) See figure 19. item 62. MCR5 and 15 only. into front case.2.4 Insert seal. to hex head screw.3. item 11. 'F' Type with Drum Figure 20. 2. item 14. item A (2 off). in accordance with Table 2.4 Fit second brake shoe without lever and hook lever with first brake shoe. into front case.2. 2.3.00 Series 32 Service Manual 2.5 Smear lip of seal.3.RE 15205 R to RE 15210 R 06.3 Combine back up ring. item 2. or seal assembly (MCR10 only).3 Fit first brake shoe with attached lever. item 2. item A (2 off) and hook springs onto back plate. item 11 (MCR10 only).3. using special assembly tool 3.2 Insert (2 off) screws. 2. 2. item 63 (6 off). E A x2 F ADJUSTMENT HOLE 2 OFF MEASUREMENT HOLE BOTH SIDES x2 2. 2. Front Case ‘F’ Type with C-M brake (MCR15 shown) brake (C-M) See figure 20. item B.D.3 Reassembling Casing.11 If brake shoe has oil on it then remove all evidence of oil from shoe. and insert into front case. with G3 grease. (6 off). onto front case assembly. into front case. to back plate.3. 2.2.8 Insert retaining springs. 2. Part Section Drum Brake Fixing Screws MCR3 Seal Detail MCR5 Seal Detail MCR10 Seal Detail Rexroth Hydraulics 12/20 .9 Depress retaining springs. item 11.2.3. item 63 (6 off). item 6.2. 2. item 63 (6 off).2. 2.

2.004") greater than measured gap.3. then refit split ring. 3500.28 Remove plastic plugs (4 off) from holes in drum brake back plate. if fitted. item 3. and fit washer. item 7.ft) 560-580 Nm (426-441 lbf. 400 680. item 6. 10 & 15 only: Set each gap in turn to 0.14 Fit wiper seal. on bench. Remove split ring. Remove split ring.3. as shown in Figure 20. 2.008" to 0.20 Using bench press and special assembly tool 7. 1250. 565 780.3.5mm (0. item 11. 3000.ft) 560-580 Nm (426-441 lbf. with thickness 0.3. Insert spacer.11 Place suitable sized cylinder underneath shaft.13 Pack front bearing cone. item 4. 2. 2. rear bearing.008") greater than measured gap. to front case assembly.22 Remove split ring. 2. then refit split ring. item 5.3. item 6.00 Table 2 Motor Type MCR3 MCR5 MCR10 MCR15 Item 63 Torque 117-122 Nm (89-90 lbf. item F.3.15 Place front casing assembly. item 2. onto shaft. item 4. 365. 750.3.3.32 Replace plastic plugs (4 off) in drum brake back plate. 470. and fit a washer. and fit split ring.16 Cover shaft spline diameter with tape.12 Warm front bearing cone.004" to 0. Table 3 Motor Type MCR3 MCR5 MCR10 MCR15 MCR20 MCR40 Items 21 & 22 No. runs free but slightly stiff in front casing assembly. shaft assembly.3. measure gap between bearing and split ring with slip gauges (this step should be completed less than 10 minutes after removing bearing from heater).31 MCR3 only: Set gap on one side to 0.002" to 0.3. and fit to shaft.3.3.05 to 0. with G3 grease. 2. item 1. 2100 2500.1 to 0. item 3. on each side through measurement holes (2 off).3. item 5.26 Check shaft.020'') by rotating relevant adjustor with a screwdriver through adjustment holes. 2. item 4. 20 & 40 only. 2.17 Fit front case assembly to shaft assembly.020'') and greater than 0. 940 1130.ft) 170-176 Nm (129-134 lbf. or front casing (MCR10 & 15 only). item 7. item 3.3. 15. 2.2 to 0. onto shaft. item 3.18 Remove tape from spline. 2. 2. 820 1120.30 MCR5.3mm (0. using bench press and special assembly tool 2. and split ring. 2. to protect lip seal. thickness 0. item 1. 225.21 With pre-load still applied. 2. Cylinder should be large enough to ensure shaft rests on cylinder not wheel studs.5mm (0. 2.1mm (0. item 1. 520.3. item 1. then refit split ring.19 Warm rear bearing cone. of 8 8 10 10 10 10 Low Displacement (cc/rev) 160.25 MCR10. item 1. item 4. item 1.020'') on the other by rotating single adjustor with a screwdriver through adjustment hole. 255. 2.23 Remove load.3.24 MCR3 & 5 only. item 10. 3000 Rexroth Hydraulics .33 Place aside and cover to protect against ingress of dirt.29 Using feeler guages/shims measure gap between brake drum.3.3. apply a load of 4 tonne to rear bearing. 1340 1780. 2. and fit a washer. Smear wiper seal with G3 grease. and brake shoe. see Figure 19.012") greater than measured gap. Rotate case during this process.3. item 7. 2. see Figure 19.3. Setting Drum Brake 2. see figure 19. 2150 2500.ft) 2. 1500 1750. 2.Series 32 Service Manual RE 15205 R to RE 15210 R 06. see Figure 19 & 20. Rotate front case 5 times during this process. 10 and 15 only.2mm (0. 2. 280 380. then press onto shaft. 2.3.3.10 MCR5. 4200 13/20 High Displacement (cc/rev) 325. to shaft (MCR3 & 5 only).27 Fit brake drum. 2. item 1. washer. 1250.5mm (0. 2. item 12. item 4.3. by pressing onto shaft using bench press and special assembly tool 6 to a load of 4 tonnes. with thickness 0.3.

to piston assembly. item 22. 2. into the cylinder block and hold in position using special tool 10. 5 Two Speed & MCR10.4.4. item 24 (2 off) to cylinder block. insert piston assemblies. High Displacement Figure 23. item 21. item 25.3 Fit piston.5 If optional springs are fitted. 2.4.7 Fit retaining rings. item 21. item 20 (Ensuring orientation of ring area as shown in part view). and roller.4 Repeat for each piston bore in cylinder block.4. item 23 (2 off). A0M MCR3. Align and secure using circlips.4 Reassembling Rotating Assembly See figures 21 & 22. Low Displacement 2.1 Check all components are clean and free from debris. items 21 & 22.2 Fit roller. item 22. item 20.6 Place the cam. item 20. Take care not to damage timing face.4. to piston bore in cylinder block. item 18. 15 Single & Two Speed Rexroth Hydraulics 14/20 . High displacement motors only 2.00 Series 32 Service Manual 2. and springs.4. over the assembled rotary group and carefully remove each special tool 10. Dip piston assembly into oil. 2.RE 15205 R to RE 15210 R 06. Low Displacement. Figure 22. Figure 21. 2. Piston Spring motors only (motor codes containing XM) 2.4.

9 Insert plug assembly.5. into correct grooves with minimum distortion of seals. item 100.4 MCR5 Single speed & MCR10 only.8 MCR5 Single speed & MCR10 only. MCR5 Single speed A0M only. Single Speed 2. item 35.5. item 27. 2.5. MCR3 Low Displacement.6 All motor except MCR5 Single speed & MCR10. Insert stop pin.5. item 26. 24 & 25. into rear case. item 28. per motor code. A0M. ensuring the stop pin fully engages with the correct distributor slot per motor code. 15/20 Rexroth Hydraulics . 2. onto stop pin. 2. Fit O-ring item 33. using a small amount of mineral based grease to hold springs in position. 2.00 Figure 24. item 32.5. item 29 (see table MCR10 A0M 4). to stop pin.7 Using special tool 11.2 Place springs. item 28. 24 & 25.1 Check all components are clean and free from debris. Assemble circlip.5 MCR20 & 40 only. to stop pin. in line with stop pin hole in rear case. item 28. Single & Two Speed 2. item 22. into rear case. item 28. Insert stop pin. fit and align distributor. A0M. Figure 25.3 Insert distributor seals. see page 4.5. see page 4.5. MCR20 & 40 Low Displacement. item 26. Fit capscrew. 2. Part Section MCR5 A0M.5 Reassembling Rear Casing Assembly See figures 23.Series 32 Service Manual RE 15205 R to RE 15210 R 06. and secure with Allen key. Single Speed 2.5. into recesses in distributor.5. 2. into correct distributor stop pin hole stamped L & R. items 47 to 51 as depicted in relevant figures 23. item 28. 2.

2. code 2W. item 59. item 56. item 57.20 Insert spring. Items 29 No. item 26 (Check that assembly is free to move).ft) 282-300 Nm (208-221 lbf. items 55. item 56. 58 and 76 into rear case.19 Ensure the correct combination of washer and spring is selected before assembly. into rear case.5.00 Series 32 Service Manual Table 4 Motor Type MCR3 MCR5 MCR10 MCR15 MCR20 MCR40 See figure 26.ft) 40-45 Nm (29-33 lbf. of 6 6 12 14 16 16 6 12 8 16 16 16 Item 53 Torque 150-155 Nm (111-114 lbf.10 Fit circlip.12 Insert O-ring. onto spool. and washer. Code "2W" Two Speed Only Alternative design.RE 15205 R to RE 15210 R 06.5. item 26.22 Oil spool and fit shuttle valve assembly. item 26 (Check that assembly is free to move).5. Two Speed Motors. only. 2. item 58.ft) 282-300 Nm (208-221 lbf. into spool valve. 2. Code "2L/2R" Two Speed Only Figure 27.5.ft) 282-300 Nm (208-221 lbf. into rear case. Fit circlip.5. into cover or brake housing. 2. items 55.5. item 55. 56. 2.ft) 75-80 Nm (55-59 lbf. item 76. Two Speed Motors.13 Oil spool and fit spool assembly. item 55. and washer. Figure 26. and washer. item 38.ft) Two Speed Motors. into rear case.5. item 26 (Check that assembly is free to move). 2. 56 and 58. 2. item 59 and item 60 into seal ring. 2. and poppet.14 Fit circlip. item 55.18 Oil spool and fit shuttle valve assembly. 56. 2. item 57.17 Insert O-rings. 2. into cover or brake housing. See figure 27b. item 38.ft) 150-160 Nm (111-118 lbf. Alternative design only. item 59. item 56. of Items 53 No. 71 and 76 into rear case.11 Insert spring. code 2L/2R only. item 58. item 71. item 26. item 26.5. item 57. item 55.ft) 117-122 Nm (86-90 lbf. items 55. into rear case.ft) 150-160 Nm (111-118 lbf.ft) 150-160 Nm (111-118 lbf. item 54 and fit seal ring to brake housing or end cover. Figure 27a. item 38.5. Code "2W" Two Speed Only 2. Rexroth Hydraulics 16/20 . onto spool.ft) Item 39 Torque 40-45 Nm (29-33 lbf. code 2W.5. 2.16 2W figure 27 only.5.5. 2. onto spool. 58. item 58. See figure 27. Insert spring.15 Insert spring.5.21 Insert O-ring.ft) 282-300 Nm (208-221 lbf.

item 2. 2. item 100. 2. MCR40 Single Speed Motors only.5. into spool bore(s) and torque to 79-85 Nm.6. item 26. MCR10 & 15 Single Speed Only 17/20 Rexroth Hydraulics . 2. 2. onto spool. as per table 4.6 Motor Assembly. Figure 28. item 62.6. 2. 2. Oil spool and fit into rear case. on front casing assembly. item 1. 2. Position cam.3 Fit rotating assembly to front casing assembly. to rear casing assembly and position rear case assembly on cam. 2. onto rear case. Remove plug. 2. item 63 (x2 on MCR20). See figure 28. 2. MCR20 Single Speed Only 2. being careful not to damage splines on shaft. 15 & 20 Single Speed Motors only. to front casing assembly. item 25. item 53.6. into cover or brake housing. item 100. item 26. Tighten opposites to maintain squareness.6.5.6. 2.6. 2. into spool bore using loctite 542 and torque plug to 42-45 Nm.5 Put Loctite 243 on capscrews. into rear case. See figures 23. See figures 29 & 30. to assembly and start all capscrews by hand before tightening.2 Fit face O-ring. Start bolts by hand.1 Check all components are clean and free from debris. MCR40 Single Speed Only 2.23 Assemble plug. Figure 30. and fill motor with clean hydraulic system oil. item 59.5.5. or cylinder block.24 Assemble plug.8 Check drive shaft to ensure motor rotates freely. Replace plug.6. aligning reference marks made before dismantling.4 Fit O-ring. item 39.26 Place end cover.00 MCR10.5. 2. per table 4. item 39. aligning reference marks.28 Torque capscrews. item 58. item 41. item 26. 24 & 25.9 A_M or C_M motors only. item 20. Tighten opposites to maintain squareness.Series 32 Service Manual RE 15205 R to RE 15210 R 06. 2. Insert O-ring. item 53.6 Fit capscrews.6.7 Torque capscrews. item 53. from rear case.27 Insert capscrews. item 38. item 41.6.5.25 Fit circlip. Figure 29. item 55. A0M C-M Motors only.

item 26.14 Place end cover. item 65.7. and gasket item 74. item 61.2±0. Ensure bush is assembled fully home in shaft. item 66.ft) 70-77 Nm (52-57 lbf. 2. 2. to rear case. Washer.1 36. as per table 5.1 48. 20 & 40). press fit new bush to shaft. item 65.7. and fill motor with clean hydraulic system oil. 2.11 Fit piston seal. Figure 31. 78.8 Apply Loctite 243 to socket head capscrews. item 20. item 67.ft) 70-77 Nm (52-57 lbf.ft) 117-122 Nm (86-90 lbf. 2. item 27. to brake assembly.1 No of Item 77 15 16 19 19 20 No of Item 78 13 14 17 17 18 No of No of Item Item 90 88 & 90 12 8 24 24 24 24 8 8 8 8 Item 90 Torque 14-16 Nm (10-12lbf. 2. into a pack. Ensure shaft fully enters cylinder block.7.7. Replace plug. Fit washer.ft) 282-300 Nm (208-221 lbf. item 88 (see table 5).7.7. item 82. item 73.RE 15205 R to RE 15210 R 06. item 70.7. item 66. Start bolts by hand. through distributor. An extra outer plate is preferred to reduce the number of required shims.ft) 35-39 Nm (26-29 lbf.7 Fit brake housing. alternates with outer discs. item 90.ft) 70-77 Nm (52-57 lbf.3 Insert brake shaft.17 Refit plug assembly.9 Fit brake pack. 2. item 94.ft) 282-300 Nm (208-221 lbf. B-M 2.1 39.5 Check pack height adding shims. 20 & 40). item 26. 2.13 Fit disc spring. item 77. ensuring correct orientation of seal to groove. (On latest motors this seal has been revised and may required a tool for assembly) 2.7.7. Ensure contact surfaces are coated with S1 grease. 2. has been removed. item 65. to rear case. item 88. to brake housing.19 Remove plug.16 Torque bolts.45±0.7. and seal.05 41±0. item 67. and an outer disc is placed at each end of the pack. items 79 & 80. Fit capscrew. item 67. Tighten opposites to maintain squareness. items 77 & 78 (see table 5). Aligning reference marks made prior to disassembly 2.ft) Item 88 Torque 70-77 Nm (52-57 lbf. item 65. 2. item 20.7. item 26 (or washer.7±0. item 89. item 90 (see table 5). from rear case. 2.ft) 117-122 Nm (86-90 lbf.1 Check all components are clean and free from debris.7. Single Speed.7. 2. item 66 (or brake piston.2 If bush. Start each screw by hand then tighten as per table 5. as required to obtain a pack height as per table 5. with washers. item 72. 2. to rear casing assembly.7 Reassembly of Park Brake (B-M motor only) See Figure 31. item 66 (or brake piston. 2. Tighten opposites to maintain squareness.00 Series 32 Service Manual 2. to cylinder block.7. item 82. item 100. Table 5 Motor Type Pack Height MCR3 MCR5 MCR10 MCR15 MCR20 MCR40 Rexroth Hydraulics 18/20 28.7. Ensure inner discs. item 61. item 26. Oil seals prior to fitting and ensure no damage to seals occurs on assembly.6 MCR5 only. Low Displacement. Clamp pack in vice.15 Insert bolts. items 77. to piston.7. item 92.ft) . 2. 79 & 80 to brake shaft. is to be included when assembling the pack. item 61).4 Assemble brake discs. onto brake housing. and tighten.7. 2.7. into brake housing. on MCR15.12 Fit piston. item 67. MCR5 only. 2.18 Close all openings with plugs.5±0.10 Fit outer seal. item 78. item 100. Shims should be placed at end of pack in contact with rear case. on MCR15.7.

item 43.2) 3. item 103.2 Remove spring.3 Fit flushing washer. item 105.2. 3. 3. into rear case spool bore.1.2. item 105. into rear case spool bore. 3.1. 3.9 Fit plug and O-ring. item 26. from rear case.2. item 107.6 Remove flushing spool.1 Fit spring.1.2.1. to poppet.00 2. Disassembly (motor may require to be disassembled prior to starting work. item 104. item 100 and washer. item 44. Reassembly 3.10 Torque plugs to 12-15 Nm. item 108. and zero brake release pressure.1. and spring.8. If necessary replace.1 Remove plug.2.2.5 Remove spring. before inserting poppet in to rear case. 3. item 104.0 3. item 102. See section 1. items 106 and 107. item 108. and shim.3 Remove poppet.8 Oil and insert poppet assembly items 103.2.7 Assemble shim (if required). 3. the brake should hold the motor torque. Figure 32.6 Torque plug to 35-40 Nm.4 Fit spring.2. scores or debris.2 With 250 bar (3625 psi) differential pressure applied to motor. and O-ring. item 26.1 Optional Accessories Flushing Valve. 3. 3.7 Remove spring. item 106. Flushing Valve and O-ring. 3.1.4 Remove plug.1 Increase pressure to brake port until motor shaft just begins to move by hand. 3. 3.Series 32 Service Manual RE 15205 R to RE 15210 R 06. 3.1. 3. item 100. 104 and 105.2. 2. from rear case. 3. items 43 and 44. if fitted. 3.8 Park Brake Test (B-M motor only) See figure 31.1. 19/20 Rexroth Hydraulics . This brake release pressure should not exceed 15 bar g (217 psi g). item 102. 3. Ensure that it is free to move.8. 2.2 Oil and insert flushing spool. from rear case spool bore. See figure 32. item 103. 3.5 Fit plug and O-ring. item 109. item 109.2.8 Inspect spool and poppet for any damage.

Motor does not rotate :. .Confirm there is pressure and oil flow supplied to the motor and the return line is clear. eg.ft) b. Motor speed incorrect :. 40-45 Nm (30-33 lbf.RE 15205 R to RE 15210 R 06. .Check motor differential pressure is correct. . Castrol LMM.Check motor mounting is correct (see installation). Energrease L21-M. 14-19 Nm (10-12 lbf. External oil leaks :. (-22°F to 302°F) eg. .ft) d. 70-77 Nm (52-57 lbf.ft) c.If still jammed confirm pump is outputting correct oil flow.P.Disconnect motor from mechanical load (ensure no pressure is applied to motor during disconnection). 5. 150-160 Nm (111-118 lbf. 7. Esso Multipurpose Grease Moly. Torque wrench covering the ranges: a.Check motor leakage flow.Strip and inspect motor. d. Then confirm motor rotates.uk Rexroth Hydraulics 20/20 . Mannesmann Rexroth Scotland Rexroth Hydraulics Viewfield Industrial Estate.ft) j. .ft) 4. 35-39 Nm (26-29 lbf. 3. rollers. . B. c. If higher than maximum specified in data sheet. .Check case drain pressure is less than 10 bar (145 psi).Strip motor and inspect cam. Tel : 01592 631777 Fax : 01592 631888 01592 631936 (Sales/Engineering) Email address : scotland@rexroth. tool description and number required. Special Assembly Tools Face Seal Assembly Tool Front Bearing (Cone) Assembly Tool Front Bearing (Cup) Assembly Tool Shaft Seal Assembly Tool Rear Bearing (Cup) Assembly Tool Rear Bearing (Cone) Assembly Tool Shaft Spacer Assembly Tool Piston Spring Assembly Tool Distributor Alignment Assembly Tool Mechanical Brake Release Washer Appendix C Fault Finding a.Strip and inspect motor for damage. . Fife. Mechanical Brake Release Bar Note Special tools can be obtained from Mannesmann Rexroth (Scotland). Shell Alvania G3 Figure 33.Ensure all bolts are torqued to correct setting. High temperature/noisy operation :. 170-176 Nm (129-134 lbf.Check motor case drain leakage is within datasheet recommendations. Replace seals. State full motor code. 117-122 Nm (86-90 Ibf. . inspect motor. b. 560-580 Nm (426-441 lbf. . Glenrothes. .Check oil cleanliness and motor pressure. Small screwdriver (no sharp edges). pistons and main bearings for wear.Check pump flow is sufficient for desired motor speed. Only to be used where specifically called out on drawing. 2. KY6 2RD.ft) g. Soft steel drift. 6. Bench press max load at least 4 tonnes.ft) i. Allen key set and double ended ring spanner set. Shell Retinax M G3 A high performance industrial grease of medium/hard consistency (NLG1 No 3).ft f.co. . Soft mallet. 75-80 Nm (55-59 lbf.Confirm leakage line is unblocked and case drain pressure is less than 10 bar (145 psi).Check charge pressure is above case drain pressure and in accordance with datasheet recommendations for operation as a pump. General Equipment (Assembly and Dismantling) 1. Slip gauges & mechanical (or hydraulic) puller. Temperature range -30°C to 150°C.00 Series 32 Service Manual Appendix A See figure 33 for special tools Appendix B Grease Specification Codetype S1 Lithium-base high temperature grease containing molybdenum disulphide (Mo S2) for specific high load/ temperature use.ft) e.ft) h. 282-300 Nm (208-221 lbf. Scotland.

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