Char-Lynn ® No. 7-119 July, 1999 Disc Valve Motor Repair Information 6000 Series (includes Big 6) Geroler® Motors -005 and -006 6000 Series Char-Lynn Motors Cross Section Drawing Char-Lynn® 6000 Series Motor Bearing Package Change Current Production -006 Version -005 Version 2 6000 Series Char-Lynn Motors Parts Drawing Seal Geroler Shuttle (Two Way) Plug Assembly Spring Geroler Seal Poppet Plug Assembly Spring Plug Assembly Seal Sleeve, Dash Pot Check Valve Plug Assembly Plug Piston Shuttle Seal Inner Face Seal Outer Face Seal Balance Ring Spring Bolt Valve Housing (Split Flange Ports) Sleeve, Dash Pot Valve Valve Plate Seal Valve Drive Geroler Drive Spring Ball Shaft and Bearing Kit (1-1/2 inch 17 Tooth Splined) Housing, Bearing Shaft and Bearing Kit (1-1/2 inch Straight) Key Valve Housing Shuttle Valve Location when Applicable Seal Plug Assembly Seal Seal Seal Bearingless Motor Mounting Flange Seal Shaft Face Seal O-ring Dust Seal Retainer -006 Optional Seal Guard Shaft Seal Back-up Ring (if Supplied) Bearing Housing Wheel Motor Screw, Cap Retainer, Front Shaft and Bearing Kit (1-3/4 in. Tapered) Dust Seal Key Retainer -006 3 6000 Series Char-Lynn Motors Parts Drawing — Big 6 Shaft Face Seal Screw, Cap Special Global Mount Shaft and Bearing Assembly Seal Shaft Seal Retainer, Front Tools Dust Seal Wheel motor and bearingless motor repair information on page 12. Shuttle valve and seal guard repair information on page 13. Seal guard reference on page 13. Tools required for disassembly and reassembly —Torque wrench (90 Nm [800 lb-in] capacity) —305 to 406 mm [12 to 16 inch] breaker bar —3/4 inch and 1/2 inch sockets —Small screwdriver (150 to 200 mm [6 to 8 inch] long, 6 mm [1/4 inch] blade) —3/16 inch Hex Key —Hydraulic Press — 1335 N [300 lbf] —Plastic or rubber hammer * —Bullet (600464) for 1-1/2 inch diameter shafts *Available by special order through our service department. Alignment studs (2) Approx. 12,7 [.50] 9,52 [.375] 215,9 [8.50] (273,05 [10.75] required for 985 cm3/r [60.0 in3/r] Displ.) 25,4 [1.00] 12,7 [.50] Dia. Steel Rod 1/2-20 UNF thread Grind flat spots on each side 4 6000 Series Char-Lynn Motors Disassembly Cleanliness is extremely important when repairing a hydraulic motor. Work in a clean area. Before disconnecting the lines, clean port area of motor thoroughly. Use a wire brush to remove foreign material and debris from exterior joints of motor. Check shaft and keyway, use 600 grit paper/cloth to remove all nicks, burrs, and sharp edges that might damage the shaft seals when installing retainer on shaft and bearing assembly. Before starting disassembly procedures, drain oil from inside of motor. Plug Assembly Valve Housing Check Plug Assembly Seal Figure 3 4 Carefully remove the following from the valve housing: 1 seal, 92,3 mm [3.63 inch] I.D. 1 seal, 7,6 mm [.30 inch] I.D. 2 check valve plug assemblies (plug, seal, spring, ball) 1 plug (case drain) with seal. Valve Figure 1 Spring (3) 1 Place motor in a vise with output shaft down. Clamp across edge of bearing housing not on housing (see Figure 1). Excessive clamping pressure on housing will cause distortion. When clamping, use some protective device on vise, such as special soft jaws, pieces of hard rubber or board. Inner Face Outer Seal Face Seal Although not all drawings show the motor in a vise, we recommend that you keep the motor in the vise during disassembly. Follow the clamping procedures explained throughout the manual. 2 Remove 4 bolts (or nuts for earlier models) from motor. Remove studs (earlier models) as shown in step 16. Balance Ring Figure 4 5 Remove 3 balance ring springs. 6 Remove balance ring subassembly. 7 Remove inner and outer face seals from the balance ring. 8 Lift off valve. Valve Drive Valve Plate Seal Figure 2 Figure 5 9 Remove valve plate. 3 Lift valve housing straight up. If done carefully, the springs and balance ring subassembly will remain on valve for easy removal. 10 Remove 95,0 mm [3.74 inch] I.D. seal from valve plate (see Figure 5). 11 Remove valve drive (see Figure 5). 5 6000 Series Char-Lynn Motors Disassembly Geroler Seal Seal Shaft Seal Retainer Back-up Ring Seal Dust Seal Drive Figure 9 Figure 6 12 Remove Geroler. Retain rollers in outer Geroler ring if they are loose. 13 Remove 2 seals (6,1mm [.24 inch]) from Geroler, 1 seal on each side of Geroler. 14 Remove drive. 17 Remove 92,3 mm [3.64 inch] I.D. seal, shaft seal and back-up ring (if supplied) from retainer. Use a small screwdriver to remove dust seal. Do not damage bore of retainer. 15 Remove 95,0 mm [3.74 inch] I.D. seal from bearing housing. 16 Use a stud remover or vise grips to remove studs (earlier models only). Then clamp bearing housing in vise as shown in Figure 7. Loosen 6 bolts. Then remove bolts and retainer. You may have to pry retainer free but do not damage housing or retainer. Shaft Face Seal Shaft and Bearing Assembly Bearing Housing Figure 10 18 Remove shaft and bearing assembly. You may need a press to remove shaft and bearing assembly (see Figure 10). 19 Remove shaft face seal from bore of bearing housing (see Figure 10). Do not damage bore of bearing housing. Note: Individual parts of the shaft and bearing assembly are not sold separately and must be replaced as a unit. Figure 7 Figure 8 6 6000 Series Char-Lynn Motors Reassembly Check all mating surfaces. Replace any parts that have scratches or burrs that couId cause leakage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe with cloth or paper towel because lint or other matter could get into the hydraulic system and cause damage. Do not use a coarse grit papers/cloth or try to file or grind motor parts. Check around the keyway and chamfered area of the shaft for burrs, nicks, or sharp edges that can damage the seals when reassembling the retainer. Note: Lubricate all seals (prior to installation) with petroleum jelly such as Vaseline®. Use new seals when reassembling the motor. Refer to parts list (6-127 6000 Series -005 and 6-159 6000 Series 006) for replacement parts and proper kit number. 21 Install shaft and bearing assembly in bearing housing (see Figure 12). Do not damage seal in bore of housing. You may need a press to install shaft and bearing assembly. Seal Shaft Seal Retainer Back-up Ring Dust Seal Figure 13 22 Use a small press, if available, to install dust seal in retainer. Metal side of dust seal must face toward retainer as shown in Figure 14. If a press isn’t available, use a plastic or rubber hammer to tap dust seal in place. Back-up Ring Dust Seal Lip Shaft and Bearingless Assembly Shaft Seal Shaft Face Seal Bearing Housing Retainer Seal Seal Seat Figure 11 20 Place bearing housing on smooth flat surface with largest open end of housing up. Apply petroleum jelly to shaft face seal. Install seal in seal seat. Seat seal properly in groove (see Figure 11 and 14). A damaged or improperly installed shaft face seal could cause internal lubrication loss and subsequent parts wear. Bearing Housing Shaft Face Seal Figure 14 Shaft and Bearing Assembly Bearing Housing 23 Install 92,3 [3.64] I.D. seal, back-up ring and shaft seal in retainer. Flat or smooth side of shaft seal must face toward retainer as shown in Figure 14. Apply petroleum jelly to inside diameter of shaft seal (after installing seal). 24 Before installing retainer, place a protective sleeve of bullet (see note below) over shaft. Grease inside diameter of dust and shaft seals. To prevent damage to seals, install retainer over shaft with a twisting motion. Do not cut or distort shaft seal. Damage to shaft seal will cause external leakage. Figure 12 Note: Bullet 600464 for 1-1/2 inch diameter shafts available—by special order through our service department. 7 6000 Series Char-Lynn Motors Reassembly Rotate Valve Clockwise 1/2 Tooth to Engage Spline 1 3 6 Anyone of 6 Ports Open to Outside of Valve Largest Open Pocket Geroler Valve 4 5 2 Figure 15 25 Lubricate threads of 6 bolts with a film of light oil. Install and finger tighten all 6 bolts. Torque bolts to 6 Nm [50 lb-in] in sequence (see Figure 15). Then final torque to 34 Nm [300 lb-in], in sequence. Note: Full torque 34 Nm [300 lb-in] on one bolt at a time can damage bolt or retainer. Valve Plate Alignment Ref. Only Note: Case Drain Holes (2) Proper Alignment Shown Case Drain Hole Pressure Relief Hole Figure 17 Timing Alignment Timing Step No. 1 — Locate largest open pocket in Geroler. Then mark location of pocket on outside edge of Geroler (see Figure 17). Seal 33 Align case drain hole and pressure relief hole in Geroler with case drain hole and pressure relief hole in bearing housing. Install Geroler on bearing housing (see Figure 17). Retain rollers in outer Geroler ring if they are loose. 34 Install valve drive in Geroler. 35 Apply a light film of petroleum jelly on 95,0 mm [3.74 inch] I.D. seal. Install seal in valve plate. Figure 16 27 Reposition motor in vise with output shaft down. Clamp across edges of retainer as shown in Figure 16. 28 Pour a small amount of light oil inside the output shaft. 29 Install 2 studs (earlier models), diagonally opposed, in bolt holes of bearing housing (see Figure 16). If you replace studs with bolts, use 2 studs for alignment purposes when stacking parts. 30 Apply a light film of petroleum jelly on 95,0 mm [3.74 inch] I.D. seal. Install seal in bearing housing (see Figure 16). 31 Install drive in output shaft (insert longer splined end of drive first), (see parts drawing on page 3). 32 Apply petroleum jelly on 2 seals, 6,1 mm [.24 inch] I.D. Install seals (1 on each side of Geroler) in case drain grooves of Geroler. 36 Align case drain hole in valve plate with case drain hole in Geroler. Install valve plate (seal side toward Geroler) on Geroler as shown in Figure 17. Timing Step No. 2 — Locate slot opening in valve plate which is in line with largest open pocket of Geroler (see Figure 17). 37 Use the following procedure for installing the valve on the valve plate. Timing Step No. 3 — Locate any one of the side openings of the valve that goes through to the face of the valve. Line up this side opening in the valve with open slot of valve plate that is in line with largest open pocket of Geroler. Rotate valve clockwise (1/2 spIine tooth) to engage valve with the valve drive spline, alignment reference shown in Figure 17 (above). This procedure provides standard timing when pressurized as shown in Figure 18 (below) . Standard Timing Pressure In Pressure In Note: Installation at this point involves 3 steps in timing the motor. Timing determines the direction of rotation of the output shaft. Timing parts include: 1. Geroler 2. Valve drive 3. Valve Plate 4. Valve 8 Clockwise Rotation Figure 18 Counter Clockwise Rotation 6000 Series Char-Lynn Motors Reassembly 38 Apply clean grease on 3 balance ring assembly springs. Install springs in 3 holes located inside bore face of valve housing (see Fig. 19). Valve Housing 43 Insert your finger through port of housing. Apply pressure to side of balance ring assembly. Hold ring in position until valve housing is in place (see Figure 21). Align case drain hole in housing with case drain hole in valve plate. Install valve housing against valve plate (see Figure 22). Balance Ring Spring (3) Seal Case Drain Seal Figure 19 39 Apply a light film of petroleum jelly on 7,6 mm [.30 inch] I.D. seal. Install seal in case drain groove of valve housing. 40 Apply a light film of petroleum jelly on 92,3 mm [3.63 inch] I.D. seal. Install seal in outside seal groove of valve housing. Pin Inner Seal Outer Seal Balance Ring Figure 20 Figure 22 Note: After installing valve housing on valve plate, check between body parts of motor for unseated seals. Plug Assembly Check Plug Assembly Bolt Figure 23 41 Apply petroleum jelly on inner and outer face seals. Install seals on balance ring as shown in Figure 20. Important: Install face seals in the positions shown in Figure 20 or the motor will not operate properly. Do not force or bend these face seals. Any damage to these seals will affect the operation of the motor. 44 Install and finger tighten 2 bolts (or studs for earlier models) opposite alignment studs. Remove alignment studs and install remaining bolts (or studs and 4 nuts for earlier models). Torque bolts (or nuts) to 98 Nm [864 lb-in/ 72 lb-ft], in sequence (see Figure 24). 3 1 Drain Plug Torque to 17 Nm [150 lb-in] (lubricated Threads) Char-Lynn ® Product number Eaton Corp. Hydraulics Div. Eden Prairie, MN 55344 2 4 Check Plug Torque to 7-14 Nm [60-120 lb-in] (lubricated Threads) Figure 21 Figure 24 42 Align balance ring assembly pins with 2 holes in valve housing (see Figure 21). Install balancing ring subassembly in valve housing. 45 Install 2 check plug assemblies (ball, spring, plug with seal). Also install case drain plug with seal, parts shown in Figure 23 and plug torque shown in Figure 24. 9 6000 Series Char-Lynn Motors Wheel Motors Key A different bearing housing is used on wheel motors (see Figure 25). Other than this, the parts are the same as the standard motor and the same disassembly and reassembly procedures apply. Seal Retainer Bolt Bearing Housing Shaft Seal Back-up Ring (if supplied) Dust Seal Nut Figure 25 Mounting Flange Bearingless Motors This motor is the same as the standard without the shaft/bearing assembly, bearing housing and retainer. The mounting flange replaces the bearing housing (see Figure 26). Follow same disassembly and reassembly procedures as rear section of standard motor. Important: Loctite® information for bearingless motor below. Drive Seal Seal Figure 26 Important: This motor requires Loctite in threaded holes of mounting flange. Follow these procedures: Adequate Loctite penetration and sealing depend highly on cleanliness and dryness of threads. Use a non-petroleum base solvent to clean excess oil from threads of flange after disassembly. You may need to use a tap to clean threads of excess old Loctite. Then, after you have fully reassembled the motor, apply 2 to 3 drops of Loctite no. 290 at top of threaded holes (see Figure 27). Note: Allow Loctite 5 minutes for thread penetration before installing motor on gear case. Attention: Do not use more than 3 drops of Loctite on threaded portion. 10 Figure 27 6000 Series Char-Lynn Motors Motors with Shuttle and, or Seal Guard Seal Guard Add-on Option Plug/O-ring* S/A (9/16-18) Torque to 23 Nm [200 lb-in] (Lubricated Thread) Plug/O-ring S/A (3/8-24) Torque to 5 Nm [50 lb-in] (Lubricated Thread) Enlarged Parts Drawing Dash Pot Poppet Plug/O-ring Spring S/A (9/16-18) Torque to 41 Nm [360 lb-in] (Lubricated Thread) Piston Poppet Spring Optional Seal Guard Dash Pot Plug/ O-ring S/A Seal Guard for Current Production -006 Version Only *Plug/O-ring S/A must be removed and drain line added for shuttle valve operation. How to Order Replacement Parts Date Code Char-Lynn ® Each Order Must Include the Following: 4. Part Number 1. Product Number 2. Date Code 5. Quantity of Parts 3. Part Name For More Detailed Information Contact Eaton Corp. Hydraulics Division 15151 Highway 5 Eden Prairie, MN 55344. Specifications and performance data, Catalog No. 11-878 Replacement parts numbers and kit information. —Parts information 6-127 (for 6000 Series -005 and -006) 00 00 Product number Eaton Corp. Hydraulics Div. Eden Prairie, MN 55344 Product Number Week of Year 01 Thru 52 Last Number(s) of Year 000 0000 000 Product Line Identification Number Product Identification Number Engineering Change Code 11 Disc Valve Motors 6000 Series Motors Product Numbers—6000 Series Motors Use digit prefix —112-, 113-, or 114- plus four digit number from charts for complete product number—Example 114-1047. Displacement cm3/r [ in3/r ] and Product Number Mounting 195 [11.9] 310 [19.0] 245 [ 15.0] 390 [23.9] 490 [30.0] 625 [38.0] 985 [60.0] Shaft Ports 1-1/2 inch Straight 1-5/16 O-ring 112-1064 -1065 -1066 -1067 -1068 -1107 -1069 40 mm Straight G 1 (BSP) 112-1094 -1095 -1096 -1097 -1098 — -1099 1-5/16 O-ring 112-1058 -1059 -1060 -1061 -1062 -1109 -1063 G 1 (BSP) 112-1088 -1089 -1090 -1091 -1092 — -1093 40 mm Straight G 1 (BSP) 113-1082 -1083 -1084 -1085 -1086 -1100 -1087 1-3/4 Inch Tapered 1-5/16 O-ring 113-1070 -1071 -1072 -1073 -1074 -1093 -1075 1-5/16 O-ring 114-1031 -1032 -1033 -1034 -1035 -1055 -1036 G 1 (BSP) 114-1043 -1044 -1045 -1046 -1047 — -1048 Standard 1-1/2 Inch 17 T Splined Wheel Motor Bearingless 114-1047 Product Numbers – 6000 Series (Big 6) Mounting Type - Standard (Code H), 4 Bolt: • 160,0 [6.30] Pilot Dia. Use digit prefix —112- plus four digit number from charts • 18,01 [.709] Dia. Mounting Holes for complete product number—Example 112-1215. • 200,0 [7.87] Dia. Bolt Circle Orders will not be accepted without three digit prefix. Output Shaft - Straight (Code 21) Ports - G1 (BSP) Staggered G 1/4 Case Drain (Code C) 112-1215 Paint - Low Gloss Black Displacement cm3/r [ in3/r ] and Product Number Mounting Shaft Ports Standard 50 mm Straight G 1 (BSP) 310 [19.0] 112-1217 390 [23.9] 490 [30.0] 625 [38.0] -1218 -1215 -1216 737 [45.0] -1247 Eaton Corporation Hydraulics Division 15151 Hwy. 5 Eden Prairie, MN 55344 Telephone: 612/937-7254 Fax: 612/937-7130 Eaton Ltd. Hydraulics Division Glenrothes, Fife Scotland, KY7 4NW Telephone: [+44] (0)1592-771-771 Fax: [+44] (0)1592-773-184 Eaton B.V. Boeing Avenue 11 1119 PC Schiphol-Rijk The Netherlands Telephone: [+31] (0)20-655 6776 Fax: [+31] (0)20-655 6800 Sumitomo Eaton Hydraulic Co. 8 Temasek Blvd. 42-01 Suntec Tower Three Singapore 03988 Telephone: [+65] 832-7727 Fax: [+65] 832-7733 Sumitomo Eaton Hydraulic Company Ltd. Ooi-Cho Kameoka-Shi 621-0017 Kyoto Japan Telephone: [+81] 771-22-9601 Fax: [+81] 771-29-2020 Eaton Ltd. 7th Floor, Woo Duk Building 832-2 Yeoksam-Dong, Kangnam-Ku Soeul 135-750 Korea Telephone: [+82] 2-557-0595 Fax: [+82] 2-557-1634 Eaton Hydraulics (Shanghai) Co. Ltd. 388 Aidu Road, Waigaogiao FTZ Pudong New Area Shanghai 200137 Peoples Republic of China Telephone: [+86] 21-5046 0758 Fax: [+86] 21-5046 0767 Jining Eaton Hydraulic Co. Ltd. 6 Ji Da Road Jining City Shandong Province 272131 Peoples Republic of China Telephone: [+86] 537-2221288 Fax: [+86] 537-2221557 www.eatonhydraulics.com Form No. 7-119 Copyright Eaton Corporation 1983, 1985, 1996, 1997 and 1999 All Rights Reserved Printed in USA 800 [49.0] 985 [60.0] -1220 -1219 ACCREDITED BY THE DUTCH COUNCIL FOR CERTIFICATION Reg. No. 24 ISO-9001 CERTIFICATED FIRM DET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS Qualitiy System Certified Products in this catalog are manufactured in an ISO-9001-certified site.