HYDRAULIC MOTOR SERVICE INFORMATION 5500mam Mm TO TO eT 7 ma o- ma oa m_- mam ma TIT TIT TF A. OVERHAUL X, HYDRAULIC MOTOR SERVICE INFORMATION The instructions contained in this section cover a complete disassembly, inspection and assembly of the gear type fluid motor. Drain all fluid from the motor and thoroughly clean the exterior surface. internal Prepare a clean, lint-free surface on which to lay the parts of the motor. + TOOLS A. Standard Tools 03/94 7/32" Allen wrench Arbor Press Awl 1-1/2" dia. steel ball Bearing puller (Owatonna Tool Co.,MD-959 or equivalent) Clean lintless cloths Deburring tool (an old file with the cutting teeth ground off) Machinist's hammer Soft hammer Loctite stud lock (red) Loctite oil seal retainer (purple) Medium grit carborundum stone Oil and grease Snap ring pliers Prick punch Sharp razor blade Scale (1/32" or 1/64" graduations) Small screwdriver Torque wrench Vise with 6" minimum open spread 10.1 5500Cc cm ce B. Special Tools a . Check valve tool 2%" om t00 LV Check valve tool is made froma 4" Ye" oun x00 Tength of 3/8" drill rod. The drawing gives details for making j this handy tool. j ce ce He 5! c_ 2. Seal removal tool c Cc Seal removal tool can be easily made from an old screwdriver. Bend the tip to fit the notch behind the shaft seal. Ce 3. Seal retainer removal tool eeceeeee This tool is handy for removing the seal retainer. It is bent from a piece of 1/4" drill rod about 14" long. ‘The ends are ground to fit the holes in the seal retainer. Dimensions are a guide and are not critical. Cc 5500 cc 03/94 10.2 cmo ma MO MO TO m7 ma cm ma mo 2. DISASSEMBLY (See motor assembly, page 10.9 for item numbers listed below) a. .Place the motor in a vise with the drive shaft pointing down. CAUTION: DO NOT GRIP ON OR NEAR ANY MACHINED SURFACES DURING ASSEMBLY OR DISASSEMBLY. INDEX MARK ALL SECTION WITH A PRICK PUNCH. BE SURE TO ALIGN THESE MARKS WHEN RE-ASSEMBLING. b. Remove the 8 cap screws (24) and washers (23) with a socket wrench. ¢. Lift off the port end cover (20). If necessary to pry loose, be careful not to damage the machined surfaces. If the thrust plate (11) remains in the gear housing (14), it can be tapped out later with a wooden hammer handle. Be careful not to distort the thrust plate. d. Lift or pry off the gear housing (14). Be careful not to damage machined surfaces. Remove thrust plate (11) as described in step c. e. Remove the drive gear with shaft and the driven gear (12). Keep these together as they are a matched set. Take care not to damage the machined surfaces of gears. f. Pry the thrust plate (11) from the shaft end cover (6), and port end cover (20), with a screwdriver or similar tool. Avoid distorting the thrust plate. , Remove and discard all rubber pocket seals (10) and gasket seals (13). g. Examine all roller bearings (9) for scoring, spauling or pitting. If replacement is necessary, pull the bearings with a bearing puller. h. Check the ring seals (8) for wear. Replace if necessary. To replace, pull the drive gear bearing (9) with a bearing puller and remove the ring seal from the bottom of bearing bore. i. Grip the shaft end cover (6) in the vise with the mounting face up. Remove the snap ring (1) with snap ring pliers. j. Pull the outboard bearing (2) with a bearing puller. k. Remove the seal retainer (3) and seal (5) with the special tool (see tool section). Remove and discard "0" ring (4). 1. Tap the seal (5) from the seal retainer (3) with the special tool (see tool section) and discard. 03/94 10.3 5500CLEANING AND INSPECTION Wash all parts in a cleaning solvent and dry thoroughly. Inspection of parts: 1. Gear Housing _ Wear in excess of .005" cut-out necessitates replacement of the gear housing. Place a straight-edge across bore. If you can slip a .005" feeler gauge under the straight-edge in the cut-out area, replace the gear housing. Pressure pushes the gears against the housing on the low pressure side. As the hubs and bearings wear, the cut-out becomes more pronounced. Excessive cut-out in a short period of time indicates excessive pressure or oil contamination. If the relief valve settings are within prescribed limits, check for shock pressures or tampering. Withdraw oil sample and check it and tank for dirt. Where cut-out is moderate, .005" or less, gear housing is in good condition, and both port are of the same size, housing may be flopped over and reused. 2. Gears - Any wear on gear hubs detectable by touch, or in excess of .002" necessitates replacement. Scoring, grooving, or burring of outside diameter of teeth requires replacement. Nicking, grooving, or fretting of teeth surfaces also necessitates replacement. 3. Drive Shaft - Replace if there is any wear detectable ~ by touch in the seal areas or at the drive coupling. .002" wear is the maximum allowable. Wear in the shaft seal areas indicates oil contamination. Wear or damage to spline, keys or keyways necessitates replacement. 4. Thrust Plates - The thrust plates seal the gear section at the sides of the gears. Wear here will allow internal slippage, that is, oil will bypass within the pump. .002" maximum wear is allowable. Replace thrust plates if they are scored, eroded or pitted. Check center of thrust plate where the gears mesh. Erosion here indicates oil contamination. Pitted thrust plates indicate cavitation or oil aeration. Discolored thrust plates indicate overheating, probably insufficient oil. 10.4 5500 ce cl cH ce ch eh ee me Cemo ma a Ta OI To m_— ma TI TF TO 1 5. Bearings - If gears are replaced, bearings must be replaced. Bearings should fit into bore with a light press fit. A neat hand fit is allowable. If bearings can fall out, bore may be oversize. 6. Seals and Gaskets - Replace all rubber and polymer seals whenever disassembling pump. Include all "Oo" rings, pocket seals behind thrust plates, shaft seal and gasket seals. 7. Check Valves - Examine small check valves in shaft and cover to make sure they are intact and functioning. If there are no check valves here, make sure the high pressure side of the shaft end cover is plugged. 4. LUBRICATION All parts, with the exception of the outboard bearing, are lubricated by the hydraulic oil in the circuit. Particular attention must be paid to keep the oil in the circuit system clean. Whenever there is a motor failure, and there is reason to feel that metal particles may be in the system, the oil must be drained, the entire system flushed clean, and any filter screens thoroughly cleaned or replaced. New ofl should be supplied for the entire system. 03/94 10.5 55005. REASSEMBLY a. Stone off all machined surfaces with a medium grit carborundum stone, If bearings have been removed, deburr bearing bores. Rinse parts in a solvent. Air blast all parts and wipe with a clean, lint free cloth before starting reassembly. b. Grip the shaft end cover (6) in the vise with the mounting face down, Examine the 2 check valves (7) to be sure they are tightly in place. Replace only if parts are damaged or missing. Check valves can be removed with the special tool (see tool section). Screw in new valve with the tool until tight. Peen with a 1-1/2" steel ball to secure. Assembly steps c, d, e, f, g and h apply to shaft end cover and port end cover. ¢. If xing seals (8) are being replaced, insert into bottom of drive gear bearing bore. The notch in the ring seal MUST BE VISIBLE. This is a check to be certain the notched side is next to the bearing. a. If any bearings (9) have been removed from the shaft end cover or port end cover, replace the bearings by pressing them into the bearing bore with an arbor press. e. Check all thrust plates (11) for wear, Replace if necessary. f£. Cut 2 pocket seals (1) 11/32" long from the pocket seal strip. Grease these pocket seals and insert into the middle slots in the thrust plate (11). g. With the pocket seals (1) down, place the thrust plate (11) over the bearings. Tap thrust plate with a soft hammer to about 1/32" from the machined surface. h. Cut 4 pocket seals (1) approximately 7/16" long from the pocket seal strip. Insert one pocket seal into each of the slots in the thrust plate (11). Push each pocket seal all the way in so that they touch the roller bearings. Tap the thrust plate down firmly against the machined surface with a soft hammer. Use a sharp razor blade to trim exposed end of the pocket seal square and flush with the thrust plate. 10.6 5500 cc ce wom eomao mT OT a a a m_— —o i. Insert the integral shaft and gear (12). Push down until the gear is tight against the thrust plate (11). Insert the matched driven gear. j. Grease the new gasket seals (13) and insert them into the grooves in both sides of gear housing (14). k. Slide the gear housing (14) over the gears (12) and tap it with a soft hammer until it rests tightly against the shaft end cover (6). Be careful not to pinch the gasket seal (13). Squirt oil over the gears to provide initial lubrication when pump is started. 1. Place the port end cover (20) over the gear journals (9) and tap lightly against the gear housing. Be careful not to pinch the gasket seal (13). m, Thread the 8 fasteners (cap screws (24) and washers (23)) into the shaft end cover (6) and snug-up alternately or cross-corner, Rotate the drive shaft (12)with a 6" wrench to make sure there is binding in the pump. n. After the fasteners are tight and you are sure there is no internal binding, torque the diagonally opposite fasteners to 200 ft. lbs. (24000 in. 1b.). ©. Coat the outside of the seal (5) with purple Loctite Seal Retainer. With the metal side of the seal down, press it into the seal retainer (3) with a 2-3/4" diameter bar and an arbor press. Be careful not to damage the lip of the seal. p. Grease and install the new "O" ring (4) on the seal retainer (3). Lightly ofl the installation sleeve and twist into the seal (5). Slide the sleeve over the drive shaft (12) and push the seal retainer into place. q- Drop in the outboard bearing (2). This is not a press fit. r. Install the snap ring (1) in the groove. s. Fill all ports with clean oil, to provide lubrication, before connecting any lines to the motor. 03/94 10.7 5500qa NTNU OU TDTU Um DUlUc Dl Uhm Thc TOU hmv DUUlLh TOU T cTUhmaUlhLUmc lr AX 7 y\ ce (Sy gies 2 SCOMMERCIAL MOTOR PARTS LIST ITEM PART _NO. QTY. DESCRIPTION 1. 02-0151 1 snap Ring 2. 02-0152 au Outboard Bearing 3. 02-0153 1 Seal Retainer 4. 02-0154 1 "o" Ring 5. 02-0155 1 seal 6. 02-0156 1 Shaft End Cover te 02-0157 2 Check Valve 8. 02-0158 2 or *4 Ring Seal 9. 02-0159 4 or *8 Rolier Bearing 10. 02-0160 12 or * 24 Pocket Seal ql. 02-0161 2 or*4 Thrust Plate 12. 02-0162 1 Integral Drive Shaft/ Gear Set 13. 02-0163 2 or*3 Gasket Seal aay 02-0164 1 Gear Housing 15. 02-0410 Oo or*1l Connecting Shaft 16. 02-0411 oO or*#l Bearing Carrier 17. 02-0412 0 or *1 Matched Gear Set is. 02-0413 0 or *1 Gear Housing 08-9034 0 or*#1 Plug 02-0165 1 Port End cover 21. 02-9015, 1 Name Plate 22. - 09-9022 2 Drive Screw 23. 09-0006 8 Lock Washer, 5/8" 24. various 8 Stud or Cap Screw, various 25. 09-9022 0 or*8 Nut, 5/8" NC * For Double Gear Motor Only 04/93 10.9 ne oe 1cc ce te he Ce ee te te Oe te te Ce ete CL| HYDRAULIC MOTOR SERVICE INFORMATION RINEER MODEL GA_15 ITEM PART NO. DESCRIPTION s iv R0150111 Seal Plate Snap Ring onc R0150112 Seal Plate Dust Seal 3. RO150113 Seal Plate Quad-Ring 4. R0150110 Seal Plate 5. RO150114 Seal Plate O'Ring 6. 0150730 Bearing Snap Ring te 0150710 Ball Bearing 8. RO150701 Keyed Shaft RO150702 Splined Shaft 9. R0150901 Bolt 10. R0150101 Front Housing - External RO150102 Front Housing - Internal at 0150430 Dowell Pins 12, 0150610 O'Ring 13. RO150620 Plate Screw 14. 0150600 Plate 15. RO150400 Stator GA 11.5 R0150401 Stator GA 15 RO150402 Stator GA 13 RO150403 Stator GA 9.5 RO150404 Stator GA 8.0 0150406 Stator GA 7.0 RO150407 Stator GA 6 0150409 Stator GA 3.0 16. R0150420 Stator Vane Spring 17. R0150410 Stator Vane 18. 0150300 Rotor 1s. R0150310 Rotor Vane 20. 0150320 Rotor Vane Spring outer 21. RO150321 Rotor Vane Spring Inner 22. 0150902 Ball Checks 23. 0150720 Needle Bearing 24. 0150800 Rear Housing 10.11 i ia PO ee