MANNESMANN REXROTH Mobile Division S Service Manual S16S Series 6 Size 4...12 RA 64759-S 04.97A 64759-S/04.97 External Gear Pump $168, Series 6 PREPARATION FOR DISASSEMBLY ‘Overhaul pump only in a clean, dust-free location, using clean tools and equipment. Dirt or grit will damage the highly machined surfaces and will result in leakage or premature failure of the pump. Before beginning disassembly, scribe match marks on the body and cover to insure that the pump will be reassembled in the same manner as it was shipped from the factory. If the body or rear cover is replaced during overhaul, scribe a match mark on the new part in the same location as on the part it replaced. DISASSEMBLY OF PUMP. NOTE All reference numbers refer to items illustrated in the exploded view provided with the parts list section of this publication. 1. Clean outside of pump with a good grade solvent and dry thoroughly. 2. On models with splined drive shaft, proceed to step 3. On models with keyed drive shaft, remove drive key (12) and snap ring (11) from drive shaft. Using a file or stone, remove any burrs from shaft end or key way. 3. Secure unit in vise (use light clamping pressure) with shaft end down; remove cap screws (1) and washers (2). NOTE During disassembly, take special note of the wear patterns on the wear plate (8) thrust plate (6) and body (15). Relate these patterns to the inlet and outlet sides of the pump. The large port in the rear cover (3) always corresponds to the inlet side of the pump. The inlet side can be further identified by the gear contact pattern in the body (gear) bore. The wear plate (8) will have a somewhat heavier wear pattern on the inlet side. The thrust plate (6) will also have a pattern that can be established for reassembly. Also note that the Tong journal of the driven gear (13) is toward the front of the pump. 4, Separate rear cover (3) from body (18) by supporting pump, shaft end up, on mounting flanges and pressing on drive shaft end in arbor press, or tap drive shaft with a plastic mallet. CAUTION Use one hand to support rear cover from underneath, since cover and internal parts will drop suddenly when dowels are disengaged. An alternate method of removing the rear cover is to pry simultaneously with two large screwdrivers in the relleved areas between body and cover. 2 Nexneva™RA 54759-81047 External Gear Pump S168, Series 6 CAUTION At no time should screwdrivers be inserted further Into pump body more than the depth of the relieved areas. Any burr must be removed from the body (15) andior cover (3) after this operation to assure a good seal between body and cover. 5. Holding pump shaft end down, remove rear cover (3). Dowel pins (7) may remain either with body or rear cover. NOTE Cover gasket (5) and thrust plate (6) may or may not remain with rear cover. Should they remain with body, remove gasket and lift out thrust plate before proceeding. 6. Lift out driven gear (13), drive gear (14), and wear plate (8. 7. Invert pump body with shaft seal up. Remove shaft seal (10) by prying it out with a large screwdriver. CAUTION Care should be taken not to damage (gouge) the shaft seal bore, because this will result in shaft seal leakage. PARTS INSPECTION 4. Wash all parts and dry thoroughly. 2, Inspect wear plate (8) and thrust plate (6). Replace if scoring or uneven wear is observed. NOTE ‘Somewhat heavier wear pattern is normal on the low pressure (inlet) side of the plates (6 & 8). However, there should be no heavy scoring in this area. 3. Remove pressure loading seal (9) and Nylatron (16) from wear plate. This seal may be two-plece or one-piece design. In either case, discard old seal or seals. All replacement seals are two-piece design and should be installed into groove. See view. The seal should extend a minimum of .005" (.127 mm) beyond surface of wear plate. Do not push seals below wear plate surface at any point. 4. Inspect bushings in body and cover. Replace cover or body if bus! burned, 198 are heavily scored or 5. Inspect gear journals and faces. Replace if faces or journals are scored or worn. 6. Inspect body for wear and scoring. If gear contact wear on low pressure side (Inlet) exceeds .005" (127 mm) depth, replace body. If the body is usable lightly remove wipe burr with suitable de-burring tool [MANNESIMANN. RexnornA BA759-S/04 97 External Gear Pump $168, Series 6 PUMP REASSEMBLY NOTE ‘The installation of new parts contained in Seal Kit No. 1516-635-024 are recommended at each overhaul of the pump. 1. Place body (15) on flat plate with shaft seal bore up. Install new shaft seal (10). Press seal into bore until itis to approximate depth shown (figure 2). Pack the area between the double lip of the seal with Lubriplate or equivalent grease. (Refer to cross section on page 5). 2. Invert body so that gear bores are up. Install wear plate (8) in bottom of bore, making sure that pressure loading seals 9 and 15 are positioned property in seal grooves and installed against bottom of bore surface. En- sure outside of “W" seal is exposed to the discharge pressure. (Or legs of “W” seal pointing toward the suction port). 3, Lubricate bushings in body and face of wear plate with SAE 10 oil. (Refer to figure 3). 4. Apply Lubriplate or equivalent to outer surface of drive shaft installation sleeve. Insert sleeve into shaft seal from front of pump unti sleeve contacts drive gear bushing. Install drive gear (14) and driven gear (19), with long journal toward the shaft seal of the pump. 5. Lubricate rear gear faces and journals with SAE 10 oil and install thrust plate (6) in its original position, bronze face toward the gears. 6. Apply a small amount of grease to rear cover seal (6) and install seal into groove. 7. Lubricate rear cover bushings with SAE 10 oll and install rear cover (3), matching scribe marks on cover and body. 8. Position pump with shaft end down, install the rear cover (3). 9. Insert cap screws (1) and washers (2); torque to $4 to 38 ft-lb. 10, On models equipped with keyed drive shatt, instal drive key (11) 11. Check that drive shaft turns with adjustable wrench without evidence of mechanical bind, BREAKIN PROCEDURE Test stand method: 4. Run pump for 1 minute at minimum pressure. 2. Raise discharge pressure to 500 psi (34.5 bar) for 5 seconds, then lower to minimum for 5 seconds. Continue cycle for 1 minute. 3, Repeat step but increase pressure in 00 psi (34.5 bar) increments until maximum operating pressure is obtained. Check flow by any method available. oeRA 64759-91047 External Gear Pump $168, Series 6 Alternate on-equipment method: 1. Mount pump on equipment and operate for 2 minutes at minimum pressure and one-quarter engine speed. 2. Increase discharge pressure to relief setting with control valve. Hold for § seconds and release. Continue cycle for 2 minutes. 3. Repeat step 2 for 3 minutes at one-half engine speed. 4, Repeat step 2 for 3 minutes at full engine speed. 5. With engine at idle speed, check pump and hydraulic system for leaks. No shaft seal leakage sufficient to form a drop is permissible. No external leakage is permissible. Output flow of an overhauled pump should meet or exceed the following: DISPLACEMENT | SPEED PRESS FLOW-MIN GEAR WIDTH MODEL | (IN‘/REV-CM=/U) | (RPM) | (PSLBARS) | (GPM -LITERS/MIN) | (INCHES/MM) stes4 | 043 7.05 100 | 2500 172 24 94 044 11.18 st6ss | 058 9.50 1900 | 2500 172 36 136 0.59 14.98 stes6 | 068 11.14 1800 | 2500 172 43° 163 0.69 17.53 stes7 | 081 1927 1800 | 2500 172 54 204 0.82 20.83 stes9 | 1.00 16.39 1800 | 2500 172 70 262 1.02 25.91 testo] 1.20 19.66 1800 | 2500 172 84 318 1.22 90.99 st6si2| 1.45 23.76 1800 | 2500 172 104 39.4 1.48 97.60 Below is a sketch clarifying the recommended shaft seal pressing tool, proper press depth of shaft seal, and installation sleeve for assembling keyed shafts. a Fou Seal nstaation Too! Figure 2. Sea! nstalation Dimension Flgue 3. Orbe Sat instalation Slave * Caution: if a new body is installed, breakin of the pump will result in wipe chips (which is normal) to be expelled from the pump outlet. These small aluminum chips can go thru the hydraulic system. A high pressure filter with a suitable flow characteristic to match the pump output flow should be installed at the outlet of the pump. This precaution will assure these chips do not result in other component failure. MANNESMANN Rexnorn 5A 64759-9104 97, External Gear Pump $165, Series 6 PARTS LIST ‘This parts list covers pump models In the SI6S series. Before ordering replacement parts, it is necessary to know the pump catalog number. The catalog number provides a key which explains and differentiates the pump features. Catalog numbers can be determined per the following example. SW S-LAH2OR Lroration vieweD From DRIVE END R-Clockwise L-Counter-clockwise SERIES NUMBER—— PUMP CAPACITY in gallons @ 2000 RPM DESIGN NUMBER 8 100 PS. DRIVE SHAFT OPTION PORT LOCATION +-Spline A-Ports in side MOUNTING PAD: 2-Straight, keyed-short D-Ports in rear OPTION T-Straight, keyed-long E-Special HASAE “AY 2-bolt ‘The parts list provides replacement part numbers for all pumps covered in this publication. Some of the parts are common for all models. These parts are listed separately under the heading of “S16S ALL MODELS". Parts that differ for the various pump models are listed under their specitic model number. To determine the number of a particular replacement part, first find the part in the exploded-view illustration and determine its index number. Then check to determine if that index number is listed under the heading ““S16S ALL MODELS” on page 7 or locate the part under the index number on page 8. 6 Nexnera™A 64759-S104.97 External Gear Pump $165, Series 6 OUTLET LARGE PORT “INLET” Do not force nylatron GEAR “FACE” 40 seal below surface i BRONZE FACE TOWARD GEARS GEAR “JOURNAL” 12 Rubber 9 - paeSsURE PRESSURE LOADING NOTE: This unit positioned for left hand SIDE SEAL 15 rotation. Rotation can be changed to right by rotating cover 3A of 3B and wear plate by 1802 Ensure legs of "W" seal point toward the suction port, INDEX QUANTITY No. PART NUMBER DESCRIPTION REQUIRED S168 All Models, 1 60101-038 Hox Head Cap Screw 4 2 61201-003 Washer 4 3A 1516-542.001 Cover-Side Port (A) 1 38 1516542.002 Cover-Rear Port (0) 1 4 76108-003 Pipe Plug 1 5 2102.04" (M) Gasket Seal 1 6 1501-047-001 (M) ‘Thrust Plate 1 7 6920-001 Dowel Pin 2 8 1516-048-004 (M) Wear Plate 1 9 116-077-003" (M) Spacer 1 10 4816076-001" (M) Shaft Seal 1 1" 63101-0085" (M) Woodruff Key (Keyed Shaft) 1 18 1816:077-004" (M) Pressure Loading Seal 1 1516-635-024 x (M) Seal Kit (includes items identified by asterisk (1) above) 1816-635-025 sx sx Major Kit identified by (M) “3 Dosgn | purnpe must be soced wih Kt TS16-605-025, " Kitt Design €oniy MANNESMANN Nexo 7RA.S4759-9/04.97, Extornal Gear Pump 8168, Series 6 INDEX QUANTITY NO. PART NUMBER DESCRIPTION REQUIRED Model $16S-4 12 116-032-001 Driven Gear 1 184 116-031-007 Drive Gear (Spline 1) 1 138, 1516-031-031 Drive Gear (Keyed 2) 1 180 1516-031-087 Drive Gear (Keyed 7) 1 14 1516-553-001 Body 1 Model $16S-5 2 1516-082-002 Driven Gear : 1 19A 1516-031-008 Drive Gear (Spline 1) 1 138 1516-031-032 Drive Gear (Keyed 2) 1 130 1516-031-038 Drive Gear (Keyed 7). - 1 14 1516-553-002 Body : 1 Model $16S-6 12 1516-032-004 Driven Gear . . 1 134, 1516-031-009 Drive Gear (Spline 1)... 1 138, 1516-031-033, Drive Gear (Keyed 2). - 1 13C 1516-031-089 Drive Gear (Keyed 7) 1 14 1616-553-003 Body 1 Model $168.7 12 1516-032-005 Driven Gear .. 1 138A 1516-031-010 Drive Gear (Spline 1) 1 138, 1516-031-038 Drive Gear (Keyed 2) 1 18 1516-031-042 Drive Gear (Keyed 7) . 1 14 1516-553-004 Body . 1 Model $168-9 12 1516-032-006 Driven Gear ... : 1 194 1816-031-011 Drive Gear (Spline 1). 1 138 1516-031-034 Drive Gear (Keyed 2). 1 13¢ 156-031-040 Drive Gear (Keyed 7) 1 14 1516-53-00 Body .. 1 Model $16S-10 12 116-092-007 Driven Gear ......... 1 134, 1516-031-012 Drive Gear (Spline 1) 1 138, 116-031-035 Drive Gear (Keyed 2) 1 18C 1516-031-041 Drive Gear (Keyed 7) 1 4 1516-553-006 Body 1 Model S16S-12 12 1516-082-010 Driven Gear 1 134 1516-031- Drive Gear (Spiine 1) 1 138 1516-031- Drive Gear (Keyed 2) 1 130 116-031- Drive Gear (Keyed 7) 1 14 1516-553-027 Body 1 Spocitications, descriptions and ilustrative material shown herein were as accurate as known at the time this publication ads oproved for printing, Rexroth eserves te igh to cerantinue models eplons a ary timer Fe'change specifications, materials, or designe without notiee and without Incurting obligation Optional equipment and accessories may add cost to the basic unit, and some options are avallable only In Combination with certain models or other options. For the avallaule combinations refer to vant data Sheets Yor the basle unt and the desired option. ‘The Rexroth Corporation Q_ttnt tysrouesovin, 1700 04 Mansel Pea, Waster, 08 40-504 Te. (90) 258340 Fo. (30) 288-3868 Inds rats Dion, 201 Cy Line oad, eee, PA 017-2191 Te (60) 4990 Fo (610) 64-8467 7 ‘llrightsreserved - Subject to revision re Nexkeva™ Printed in USA,