gradall Crawler Vendor Service Manual

XL SERIES CRAWLER MAINTENANCE MANUAL

Form No. 29635 Original Issue 3/97 Rev. 9/00

NOTE! “High Pressure” denotes 10,000 psi gauge “Low Pressure” denotes 1,000 psi gauge

Form No. 29635 3/47

(i)

MAINTENANCE MANUAL XL CRAWLER UNDERCARRIAGE

Introduction Orientation: Right, left, front and rear relate to the direction of a person sitting in the upperstructure cab. The front of the machine is the idler roller end. The excavating excavating (working) function function should always be performed over the fron f rontt to minimize track component wear. Related Materials: Other manuals related to your machine should be reviewed for information about a specific subject other than XL CRAWLER UNDERCARRIAGE maintenance. Other manuals available for your machine: Operator’s Manual Service Manual Safety Manual Sales Literature Parts Manual Brochures Miscellaneous Vendor Manuals covering specific components

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3/97

(ii)

Introduction (continued) This Manual covers technical repair and maintenance information for the CRAWLER UNDERCARRIAGE of the XL SERIES GRADALL Charts showing component dimensions, part numbers, wear percentage, fastener torque values, hydraulic hose and fitting torque values and lubrication capacity information are included. Information about track chain adjustment, repair and replacement is also supplied. This Manual does not cover machine operation or the hydraulic system. Refer to appropriate manuals for that information. Familiarize yourself with this Manual and its contents. Should you have questions concerning information supplied or a specific machine, please contact your GRADALL distributor for assistance.

Safety The following symbols are used to call your attention to safety notices.

!

DANGER

DANGER: This symbol indicates an extreme hazard which could result in high probability of death.

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WARNING

WARNING: This symbol indicates a hazard which could result in death or serious injury if proper precautions are not taken.

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CAUTION

CAUTION: This symbol indicates a hazard which could result in injury or damage to equipment or property if proper precautions are not taken.

DAILY: Read and adhere to all safety notices placed on the machine and in the various technical and operator’s manuals. Clean the machine as required. Be sure all grab handles, steps, and walking areas are clean and clear. Be sure the fire extinguisher works. Check that all safety decals are in place as when the machine was received new. Be sure all safety and operator’s manuals are with the machine. Report any safety hazard to the correct personnel. DO NOT operate the machine in an unsafe manner. DO NOT operate the machine if you are unfamiliar with the controls. DO NOT operate the machine if you are under the influence of alcohol or drugs. Be certain controller shut-off safety switch functions properly when the operator’s seat handle is raised.

!

WARNING

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DO NOT remove track tensioning hydraulic cylinder fitting while it is pressurized. Relieve pressure by loosening the fitting one or two turns until grease escapes through the vent slot and pressure is relieved. Refer to the warning decal on the inside of the side frame cover protecting the track tensioning device.

(iii)

MAINTENANCE MANUAL XL SERIES CRAWLER UNDERCARRIAGE

I. Nomenclature FIGURE 1 GRADALL CRAWLER UNDERCARRIAGE

This Manual covers the undercarriage mechanical running gear. Components such as planetary drive, hydraulic drive motor and crawler brakes are not covered. Refer to the respective manual for information on these components. The undercarriage frame (carbody and side frame) is only covered in welding repairs. A quick reference chart is supplied as an aid to find major components in their respective parts manual. Refer to the contents page for specific components covered in this Manual.

How to extend Undercarriage life 

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

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Dig only with the attachment over the idler end of the tracks. This gives even pin and bushing contact, reducing wear. An attachment working over the sprockets will result in overloading the surfaces between the sprocket and track bushing. Travel in the forward position with the sprockets at the rear end of the machine. Travelling in reverse causes excessive wear on the sprockets and chains. When turning, utilize both tracks. Using power to one track only causes the opposite track to drag, wearing components more rapidly. Keep back and drive components clean and free of mud and debris.

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I. Nomenclature (continued) 







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

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Perform daily inspections, checking for loose bolts, leaking seals, structural damage, correct track adjustment and any abnormal wear. Report problem areas to appropriate personnel. Operate the machine in a smooth professional manner, especially over obstacles or rough terrain. This will usually prevent premature roller and component wear and reduce the possibility of track shoe bending. Always park the machine on level ground. If parked on an incline or uneven terrain, the roller seals could become deformed or damaged resulting in lubricant loss. Without lubricant the internal parts of a roller will be destroyed within hours. Keep the machine lubricated per lube chart. Replace or rebuild track chain components as required. Refer to the “Track Chain” section of this Manual for specific component information. Keep a supply of metric fasteners in stock to replace broken or lost components. When replacing bolts, nuts, hydraulic hoses and/or hydraulic fittings, torque them to the values shown in the torque charts on pages 28-30 of this Manual.

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II. Track Adjustment FIGURE 2 TRACK ADJUSTMENT CHECK

Proper track adjustment is achieved when the link assembly is properly tensioned. This condition is reached when the maximum sag between the top carrier roller and the drive sprocket matches the dimension “A” shown on Figure 2. The allowable sag for your machine is as follows: XL 5200-35mm-1.375 in. XL 4200-35mm-1.375 in. XL 2200-20mm-0.781 in. Track Adjustment Procedures: Clean track components so foreign material does not obstruct the tensioning assembly from full free movement. 

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Install a straight edge on the track and measure sag per Figure 2 . If tightening adjustment is required, add grease to the tensioning cylinder until the proper dimension “A” in Figure 2 is achieved. TO ADD GREASE TO THE TENSIONING CYLINDER, PROCEED AS FOLLOWS:

FIGURE 3 SIDE FRAME TRACK TENSIONING DEVICE COVER



FIGURE 4 WARNING DECAL

Remove the track tensioning device cover from the side frame. See Figure 3. Follow the warning decal instructions on the inside of the cover. See Figure 4.

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II. Track Adjustment (continued) FIGURE 5 BUTTON HEAD HYDRAULIC FITTING

FIGURE 6 FILL VALVE (TRACK TENSIONING CYLINDER)

Attach the button head hydraulic fitting (furnished in the tool kit) to the fill valve that is screwed into the tensioning cylinder. See Figure 5 and Figure 6.

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NOTE! The XL 5200 also has a relief valve installed in the tensioning cylinder. 

Pressurize the cylinder until the proper dimension “A” is achieved. See Figure 2.

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Reinstall the track tensioning device cover to the side frame. See Figure 3.

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IF THE TRACK TENSION IS TOO TIGHT AND NEEDS LOOSENING PROCEED AS FOLLOWS: Remove the track tensioning device cover from the side frame. See Figure 3. Follow the warning decal instructions on the inside of the cover. See Figure 4.



Carefully back out the hydraulic fill valve from the tensioning cylinder until lube starts to escape from the relief slot machined in the threads. See Figure 5 and Figure 6.



Release the amount of lube necessary to achieve proper dimension “A” in Figure 2 for your machine.

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FIGURE 8 FILLVALVEANDBUTTONHEADFITTING INSTALLED IN TENSIONING CYLINDER

FIGURE 7 TENSIONING CYLINDER FILL VALVE WITH BUTTON HEAD FITTING

NOTE!

Figure 7 and Figure 8 show the tensioning cylinder fill valve and the button head fitting that fits to it. Be certain you understand how to install the buttonhead fitting to the fill valve (one-way check valve) before attempting adjustment.

Reinstall the side frame cover.



!

WARNING

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Do not remove any parts until all pressure in the tensioning cylinder has been relieved. Serious injury could occur. Refer to the decal on the undercarriage side frame tensioning cylinder cover.

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II. Track Adjustment (continued) Improper Adjustment Hazards: TRACKS TOO TIGHT: If track is too tight, excessive friction will cause a reduction in machine performance and may cause accelerated wear of rolling track components. TRACKS TOO LOOSE: If track is too loose, component service life is drastically reduced. Loose tracks easily become misaligned and may jump off the sprockets when the machine is turned. A loose track may also jump sprocket teeth causing damage or premature wear. At best, loose tracks make it difficult to travel in a straight line.

NOTE!

Both tracks must be adjusted equally to ensure proper travel performance.

III. Shoe Contact with Rock Guard Contact with the rock guard may result in wear on a portion of the leading edge. The track chain may flex up between rollers as the machine travels over the ground. The amount that the chain can flex in this direction is increased when internal pin and bushing wear occurs. As the chain flexes up, the leading edge of the shoe may contact the rock guard. (See Figure 9) . Also, rail and track roller tread wear reduces the clearance between the track shoes and the rock guards. This would increase the possibility of contact. Normal contact may also occur if the track chain is tipped up on one side by rough terrain. This type of wear does not affect the function of the track shoe and, therefore, is a minor wear pattern. It does, however, reduce the bending strength of the shoe. FIGURE 9 SHOE CONTACT WITH ROCK GUARD

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MAINTENANCE MANUAL

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XL SERIES CRAWLER UNDERCARRIAGE

IV. Crawler Travel Speed Adjustment for crawler undercarriage travel speed is performed of the control valves. See Figure 10. There are stroke limiters provided on each crawler propel valve end cap. Use the following tests to set freerunning speed and actual travel speed. A stopwatch and point (for marking the tracks) will be required for these tests. Before checking travel speed, be certain the tracks, chains, and rollers are free of mud, and other debris that could interfere with achieving correct test results. Check track tension before testing travel speed. If track tension is not correct, perform track adjustment procedures outlined on pages 3 and 4 of this Manual.

Travel Speed Testing and Adjustment Procedures:

1.

Rotate the upperstructure so the boom is perpendicular to the right-hand track. Place the bucket on the ground with the boom extended. Apply down pressure to the boom to raise the right hand track off the ground. Paint a stripe on the track to be used as a reference point.

2.

Set the crawler speed to “High”. Push the right-hand forward travel pedal. When the paint stripe reaches your desired location, start the stopwatch and time the track for one complete revolution. The correct speed is as follows: XL 5200: 8.6 to 9 seconds (27.9 RPM sprocket speed). XL 4200: 7.8 to 8.2 seconds (27.9 RPM sprocket speed). XL 2200: 3.9 to 4.3 seconds (55.7 RPM sprocket speed).

3.

If travel speed needs corrected, remove the plug from the rear stroke limiter. Insert an allen wrench in the stroke limiter screw. Loosen the stroke limiter housing and adjust it to achieve the correct travel speed. Turning the stroke limiter screw clockwise decreases travel speed, turning it counter clockwise increases travel speed. Re-test travel speed after adjustment. See Figure 10.

4.

Repeat test for right-hand reverse travel using the front stroke limiter. After this travel speed is set, carefully raise the boom to lower the right hand track to the ground.

5.

Rotate the upperstructure so the boom is perpendicular to left-hand track. Repeat forward and reverse track speed test for the left hand track using steps 1 thru 4.

6.

After free-running speed has been checked, mark off a level, linear distance of 100 feet. Set the crawler undercarriage for high speed and enter the 100-foot marked course travelling straight and at full travel speed forward. Begin timing as the machine enters the course and end timing when it exits. Correct travel speed is as follows: XL 5200: 30.3-30.9 seconds. XL 4200: 27.8-28.4 seconds. XL 2200: 19.5-20.1 seconds.

NOTE!

7.

If travel speed is slower than the above times and free-running speed was tested correctly, do not increase track speed to achieve the above times. Use free-running speed as the maximum speed for the crawler undercarriage.

Repeat step 6 for reverse travel.

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IV. Crawler Travel Speed (continued) FIGURE 10 CRAWLER SPEED ADJUSTMENTS

V. Crawler Tracking Crawler Undercarriage Tracking The crawler undercarriage is allowed a small deviation from straight travel. If this deviation is excessive, it can be adjusted using the crawler propel valve stroke limiters. Whenever tracking is adjusted, the freerunning travel speed of the undercarriage must be checked to ensure it does not exceed specifications for the model being tested. It may be necessary to slow one track, rather than speed up the other.

1.

To Check Undercarriage Tracking Proceed as Follows: Mark off a level, linear distance of 100 feet. Set the crawler undercarriage for “High” speed. Enter the 100-foot marked-off course straight and at full travel speed forward.

2.

After completing the course, measure the machine’s path of travel for deviation from a straight line. Maximum allowable deviation is 10 feet. If free-running speed has been checked and is correct, it is best to slow the fast track when adjusting tracking. The stroke limiter adjustment screw should not be adjusted more than 1/8 of a turn before retesting. The stroke limiter adjustment is very sensitive. Use the rear stroke limiter to adjust forward travel.

3.

After forward travel tracking test is complete, repeat for reverse travel. Use the front stroke limiter to adjust for reverse travel. See Figure 10.

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VI. Track Chain FIGURE 11 TRACK PIN & BUSHING

The track chain assembly known in the industry consists of a series of links, pins and bushings on which the track shoes are bolted. The chain contacts the drive sprocket on one end of the machine and the idler roller chain tensioning assembly on the other end. As the sprocket turns, the teeth contact the bushings pulling them around the circumference resulting in machine travel. The links are fastened together by pins and bushings which are sealed. See Figure 11 and Figure 18. The chain must be installed with the pin end of the links facing the back of the machine at ground level. To split open a track, first locate the master pin. It has a (machined center) countersink in the center of each end. See Figure 18. Then position the track so it is accessible. Use a portable press to push the pin out. The chain is now broken apart and both ends are free.

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WARNING

Stay clear of the end of the chain to prevent injury should it roll uncontrolled to the ground. We recommend you use a “come-a-long” or similar fastening device to lower the end of the chain to the ground.

Reverse the procedure for reassembly.

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VI. Track Chain (continued) The accumulated operating (traveling) hours on the machine result in link wear. Replace whenever the 100% value is reached. Allowable link wear is per Table 1: FIGURE 12 TRACK LINK

TABLE 1 TRACK LINK WEAR PERCENTAGE DATA

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VI. Track Chain (continued) Track Shoes The standard track shoes (pads) used on the GRADAlL crawler machines are the triple grouser type. This design gives a lower penetration into the surface, reduces turning resistance, improves maneuverability and reduces loads on other undercarriage parts. Other style track shoes are also available. To minimize shoe bending or breaking, do not use a wider shoe than is required. It is important to keep the track bolts properly torqued. (Refer to bolt torque chart on pages 28-30 of this Manual) Approximately every 100 hours the bolt torque should be checked. Visually check for loose or missing bolts at the start of each operating shift. If track shoes show a tendency to bend or break, the shoes may be too wide for the working surface. Maximum back shoe wear of 100% ( See Table 2 for values applicable to your machine) is allowable if the machine is normally working on medium soft ground. Operating on rocky ground the shoes must be replaced when the wear is 75%. ( Second column from right, Table 2. )

FIGURE 13 TRIPLE GROUSER SHOES

TABLE 2 TRIPLE GROUSER SHOE WEAR PERCENTAGE DATA

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VI. Track Chain (continued) Track Pin The hardened (surface hardness Rc 60) track pin is pressed into the right and left link of the chain. It is also installed through the bushing at each end of the link. There are seals at each end to prevent contamination. The outside diameter (O.D.) of the pin wears against the inside diameter (I.D.) of the bushing with which it is making contact. See Figure 14. For allowable track chain wear tolerances, see “When to Repair Track Groups,” Figure 19 and Table 4. Once the pin reaches the allowable wear limit it may be rotated 180 degrees for extended life. See Figure 15.

FIGURE 14 TRACK PIN

FIGURE 15 TRACK PIN TURNING

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VI. Track Chain (continued) Track Bushing The track bushings fit into the counterbore of each link. There is one bushing per link set. The track pin fits through the bushing. The O.D. of the bushing contacts the teeth of the drive sprocket during travel. This results in bushing wear at the sprocket side only. This wear along with pin wear is a major factor in causing looseness and damage to the chain by increasing pitch length. Outside wear of the bushings is of three types: Radial Wear, Forward Drive Side Wear, and Reverse Drive Side Wear. (See Figure 16) Measurements should be taken at each position; use the one which indicates maximum wear. (Refer to Table 3).

FIGURE 16 TRACK BUSHING WEAR

TABLE 3 OUTSIDE BUSHING WEAR

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VI. Track Chain (continued) FIGURE 17 MASTER PIN

MACHINE CENTER (COUNTERSINK)

Master Pin and Bushing A master pin and bushing is used on each track. These components are the ones used to take the track apart and put it together. See Figure 17. The master pin and bushing wear more rapidly than do other pins and bushings. This is because the bushing does not extend into the counterbore of the link. The master pin can be identified by the countersink (center) machined in the center of each end. A portable press is used to remove the master pin.

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WARNING

Once the master pin is removed, the track may roll uncontrolled to the ground. To avoid injury, stay clear.

FIGURE 18 TRACK PIN SEALS

The track chain link is sealed at each end of the track pin. This design helps guard against contaminants, a major source of premature wear. The seals must be installed. See Figure 18. When the pins and bushings are assembled they must be well lubricated.

Track Bolts The track bolts have special wear-resistant heads, self-locking, square nuts and rolled threads. These bolts meet American standard Grade 8 and European standard 12.9 class. Torque values are found in the torque chart. See Pages 28-30. The bolts should be randomly checked for torque approximately every 100 hours. Check for loose or missing bolts at the start of each operating shift.

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VI. Track Chain (continued) When To Repair Track Group Once you determine exactly when to replace each worn part of your undercarriage, you have maximized your opportunity to exact the most economical use of your undercarriage. This Manual contains tables showing the maximum wear limit for each track moving part. If these limits are observed, you will realize economical performance without costly expenses resulting from component damage, replacement parts and machine downtime. For measurement of component wear, a few simple tools are needed: flexible tape, small caliper, large caliper, depth gauge, steel ruler and straight edge.

Links, Pin and Bushing Wear Measurement To establish the average wear measurement, choose a length of 4 sections of link assembly on top of the undercarriage in a well tensioned zone. Do not include master pin and link in the four sections of link measured. See Figure 19 and Table 4. Once the wear measurement reaches the 100% limit the pins may be turned 180 for extended life. If this operation has been previously performed the worn parts must be replaced. FIGURE 19 FOUR SECTIONS OF THE LINK ASSEMBLY

TABLE 4 WEAR DATA: 4 SECTIONS OF THE LINK ASSEMBLY

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VII. Track Rollers FIGURE 20 TRACK ROLLER

The track rollers used on the XL SERIES GRADAlL CRAWLER are sealed units that normally require no resealing or refilling (unless they have been damaged). The rollers are filled with SAE 30 or SAE 40 weight oil. To fill the roller, remove the fill plug from the body and fill with the quantity of oil shown for your machine in Table 5. The XL 5000 and XL 4000 use the bottom roller design for the top and bottom of the track. The XL 2200 uses a bottom design on the bottom of the track and a carrier design roller for the top of the track. Refer to the quick reference chart or the applicable parts manual for part number identification.

TABLE 5 TRACK ROLLER LUBE CAPACITY CHART

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VII. Track Rollers (continued) Roller Seals If the seal group is being replaced, use new parts only. Used seals will most likely fail shortly after rebuild. Installation procedure for roller seals is as follows:

1.

The mating surface where the seals contact must be dry and clean, free of dirt, nicks and burrs.

2.

Install O-ring on the roller shaft.

3. 4. 5.

Install the seal group into the roller shell seat. Remove the plastic band holding the rings together.

6.

Fill roller with lube. See Table 5.

Press the collar onto the roller shaft and lock in place with the dowel. Invert the roller assembly and perform steps 1 through 4.

FIGURE 21 ROLLER SEALS

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VII. Track Rollers (continued) Track Roller Disassembly (See Figure 21)

1. 2. 3. 4.

Remove lube fill plug and dump lube into a container. Press dowel pin out of collar. Remove seals and shaft. Press out bushings.

Track Roller Assembly (See Figure 21)

1. 2. 3. 4.

Install bushings into roller shell.

5. 6. 7. 8. 9.

Install seal group in roller shell seal seat.

Install collar to roller shaft. Install dowel pin through collar and shaft. Install O-ring in roller shaft.

Insert collar and shaft into shell until collar bottoms to the seal group. Invert roller 180. Complete component assembly as in steps 2 through 6. Fill Roller with lube. See table 5.

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VII. Track Rollers (continued) Bottom and Carrier Track Rollers The rail diameter of the bottom and carrier roller for your machine when it was new is shown in Table 6 and 6 and Table 7. Whenever 7. Whenever the wear percentage reaches the 75% range the roller diameter should be resurfaced to size or the roller replaced. The track roller rail surface hardness is Rc 55.

FIGURE 22 BOTTOM ROLLER

FIGURE 23 CARRIER ROLLER XL 2200

TABLE 6 BOTTOM ROLLER WEAR PERCENTAGE DATA

TABLE 7 CARRIER ROLLER WEAR PERCENTAGE

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VIII. Idler Roller with Track Tension and Adjuster Compartments FIGURE 24 IDlER ROLLER:TYPICAL

The idler roller assembly is located at the front of each side frame. Major components are Idler Roller, Tensioning Spring, Hydraulic Adjusting Cylinder, Idler Slides and Connecting Bracket. This assembly acts as a shock absorber for the track system. It compensates for shock loads (caused by large rocks, uneven terrain, etc.) imposed by momentarily adjusting the chain pitch. Compensation is accomplished by the tensioning spring and hydraulic cylinder collapsing the required amount, thus minimizing the chance of chain breakage. The XL 5200 hydraulic adjusting cylinder is equipped with a relief valve to assist in accepting major shock loads that could be imposed on this size machine. The relief valve will relieve lubrication to compensate for excessive shock loads. Should this occur very often it may be necessary to recharge the cylinder with lubricant once the travel cycle returns to normal. Form No. 29635 3/97

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VIII. Idler Roller with Track Tension and Adjuster Components (cont.) FIGURE 25 IDLER ROLLER

The idler roller has two outside rails which is the area that the track links make contact. These rails are hardened to Rc 55. The rollers are “lifetime” lubricated and under normal working conditions no further lubrication maintenance is required. The idlers should be randomly checked while working to protect against destruction should a seal be damaged. To install lubrication we recommend the use of a low pressure pump with a nozzle on the end that will fit through the fill hole in the idler body. Use SAE 30 or SAE 40 oil at capacities for your machine. See Table 8.

TABLE 8 IDLER ROLLER LUBRICANT CAPACITY

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VIII. Idler Roller with Track Tension and Adjuster Components (cont.) Idler Roller Disassembly (See Figure 25) ASSUMPTION: RECOIL COMPONENTS HAVE BEEN REMOVED AND THE ROLLER IS FREE.

1.

Remove one of the dowel pins that fasten the bracket to the shaft.

2.

Remove the remaining components which are now free of the shaft.

3.

Press out the bushing. (The bushing can only be removed by use of a vertical press with correct tooling.)

4.

If necessary, remove the remaining dowel pins and bracket.

Idler Roller Assembly (See Figure 25)

1. 2. 3. 4. 5. 6. 7.

Press the bushings into the idler shell. Mount a bracket on to the shaft. Insert seal group into the idler shell seal seat. Install O-ring on the shaft. Insert the complete sub assembly in the idler shell to the point where it bottoms the seal group. Invert the idler and assemble components as in steps 1 through 4. After loose assembly press tightly together using a vertical press.

NOTE! The seal group is assembled the same as in the bottom rollers. See Figure 21. Idler Roller and Track Tensioner Removal and Replacement to the Side Frame !

Serious injury could result if the pressure is not relieved from the tensioner and recoil system.

WARNING See decal on the side frame cover and “Track Adjustment” section of this Manual.

To remove pressure from the cylinder, carefully back off one or two turns on the fill fitting. (Refer to Track Adjustment section of this Manual.) As soon as lube starts to come out the vent hole STOP backing off the fitting. Once pressure is relieved it is safe to remove the roller and tensioner assembly. It will be necessary to collapse the tensioning cylinder fully for reassembly of the group. See Table 9 for the part number and stroke of the cylinder for your particular machine. TABLE 9 IDLER ROLLER TENSION CYLINDER

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VIII. Idler Roller with Track Tension and Adjuster Compartment (cont.) Track Tension and Idler Roller Disassembly

1. 2. 3. 4. 5. 6. 7.

(See Figure 24)

Relieve all pressure from the track tensioning cylinder. See Figure 3 and Figure 4. Carefully separate the track chain and lay it on the ground. Remove the recoil device group (refer to the correct page in the Parts Manual for your machine). Remove the track tension group (refer to the correct page in the Parts Manual for your machine). Remove the two (slide brackets) support groups and idler pin from the side frame. Remove idler roller from the machine. Examine all fasteners and seals for damage. Replace any damaged component.

Track Tension and Idler Roller Reassembly

1. 2. 3. 4. 5. 6. 7. 8.

Clean, lubricate, and check all components for damage. Reassemble idler roller with support group and fork and install into side frame (refer to Parts Manual for parts required). Install track tension group (refer to Parts Manual for parts required). Torque all fasteners to correct value. Reassemble track chain to side frame and lack master pin and bushing as required. Using button head coupling (8381-3109) supplied in the GRADALL Tool Kit, pressurize the tensioning cylinder to achieve the correct track adjustment. (Refer to Track Adjustment section of this Manual.) Install cover over the opening in the side frame for the valve that is used for the tensioning cylinder adjustment. Check that the “WARNING” for track adjustment is in place. If it is not on the inside of the side frame cover, (installed at step 7) or is illegible, notify the correct personnel to have it replaced immediately.

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VIII. Idler Roller with Track Tension and Adjuster Components (cont.) Idler Roller Rail Weld Refacing TABLE 10 WEAR PERCENTAGE DATA

Figure 26 and Table 10 show the allowable wear on the rail height of the idler roller. A good undercarriage shop has the ability to rebuild (reweld) the roller to its original dimensions. When wear percentage reaches 100% the idler roller must be rebuilt or replaced.

FIGURE 26 FRONT IDLERS

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IX. Drive Sprocket The drive sprocket is sized to provide proper travel performance for the model machine on which it is used. It is bolted to a gear box that is also sized for correct performance. The drive sprocket always has an uneven number of teeth. As they rotate the drive chain is engaged which results in machine travel.

The six major types of drive sprocket wear are:

1.

Drive Chain Wear --- when operating forward.

2.

Reverse Drive Side Wear --- when operating in reverse.

3.

Climbing Wear --- result of increased track pitch.

4.

Root Wear --- when bushings slide from side to side.

5.

Rotative Wear --- when bushings rotate as they leave (forward) or enter (reverse) the sprocket. Reverse Drive Side Tip Wear --- when sprocket pitch is greater than track pitch. The drive sprocket is cast of special manganese steel hardened to Rc 55. If it is reconditioned by welding it must conform to the dimensions of a new sprocket. Table 11 gives the new and allowable wear tolerances of the sprocket on your machine. TABLE 11 NEW DRIVE SPROCKET DIMENSIONS

FIGURE 27 DRIVE SPROCKET

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IX. Drive Sprocket (continued) Wear on the sprocket is very difficult to measure. As the machine works, wear takes place in such a way that no trace of the original teeth are left for use as a measuring point. Sprockets should be rebuilt or replaced whenever wear percentage reaches 100%. ` Wear is never uniform, so measurements should be taken at different points on the sprocket teeth. See Figure 18. Use the area showing the most wear as your gauge for determining wear percentage on Table 12. Dimension “0F” from Table 11 is the original diameter of your respective sprocket. Dimension “0G” is the dimension to the centerline of the bushing for your back as it lays against the root of the sprocket tooth when new. TABLE 12 DRIVE SPROCKET WEAR PERCENTAGE

FIGURE 28 TOOTH DEPTH

Drive Sprocket Removal from Drive Mechanism To remove the drive sprocket from the machine, proceed as follows: Release pressure from the track tensioning device per safety decal instructions (Refer to track Adjustment section of this Manual.)

1.

Separate the track chain at the master pin and bushing. See Figure 17.

2.

Carefully lay the drive chain on the ground. Use good SAFETY practices to prevent injuries.

3.

Attach lifting or holding device to the sprocket to prevent uncontrolled falling once it is free of the machine.

4.

Remove the socket head capscrews holding the weldment to the planetary drive.

5.

Lift the sprocket to the work area as required.

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IX. Drive Sprocket (continued) Drive Sprocket Reassembly to Drive Mechanism To reassemble the drive sprocket, proceed as follows:

1. 2. 3. 4. 5. 6. 7.

Clean all areas of the side frame and drive mechanism where the sprocket fits. Use “Never-seez” on mounting surfaces (pilots). Lift drive sprocket into place (pilot mounting surface). Install mounting capscrews (socket head metric). Torque mounting screws to correct value as required. Refer to Table 13 and 14. Lift track chain in place and fasten together at the master pin and bushing. Adjust the track chain to correct specifications.

X. Miscellaneous Towing If power is lost to the crawler drive and it becomes necessary to tow the unit proceed as follows:

1. 2. 3. 4. 5. 6. 7.

Remove the sheetmetal guards from the drive mechanism as required for access to the planetary drive. Remove the planetary drive cover mounting socket head capscrews and store in a safe place for reuse. Remove the sun gear from the planetary drive and store in a safe place for later reuse. Reinstall the planetary drive cover. Perform steps 1 through 4 on the opposite track. Install towing chain and/or cable to towing area on the carbody. Carefully tow the machine to the area designated. When the machine is to be put back into service, it will be necessary to reinstall the removed sun gear to the planetary drive. Retorque fasteners to correct value per the torque chart. Reinstall any sheetmetal protective covers removed. Lubricate the machine per specifications before resuming normal operations.

Undercarriage (Carbody and Side Frames) The undercarriage (carbody and side frames) of the GRADALL CRAWLER is designed correctly for the size machine it is mounted under. The integrity of the design is assured during manufacture by the use of intricately designed welding and machining fixtures. Welding Repairs Should welding repairs be required, adhere to the following procedures:

1. 2.

Disconnect the battery leads to prevent electrical component damage.

3.

Use welding rod or wire conforming to AWS 7018 low hydrogen process.

Position the ground clamp adjacent to the area being welded. This will prevent arcing between components such as bearings, etc. which could cause damage to them. Do not ground through rotating parts.

Form No. 29635 3/97

26

X. Miscellaneous (continued) Piston Motor A bent axis piston type motor is fastened to the planetary drive at the sprocket end of the side frame. It can be shifted from low speed to high speed or vice versa as required. Refer to the Crawler Hydraulic Schematic and the Vendor Service Manual for more detail. Planetary Drive and Crawler Holding Brake A planetary gear reduction box and disc brake assembly is connected to the drive sprocket. The brake is normally set. It is released by hydraulic pressure whenever the travel cycle is activated and remains disengaged as long as the travel circuit is pressurized. The brake is not a dynamic stopping brake. It is a holding brake only. Track Guides The function of the track guides bolted to the side frame is to keep the track chain in line. It also may keep the track chain from jumping the sprockets when turning if the chain pitch is outside the allowable tolerances. Planetary Drive and Crawler Holding Brake (continued) The planetary gear box operation is explained in a separate Manual supplied by the Vendor. Refer to that manual for information on the function of this assembly. Refer to the lubrication chart for the type and capacity of the gear box. Bolt Torque Charts The following bolt torque charts (Table 13 and 14) covering English and Metric fasteners are the ones used by GRADALL Ratings are for lubricated fasteners. Do not exceed the allowable rating. An overtorqued bolt in most cases will fail as rapidly as an undertorqued one. Bolt sizes and torque values are shown in most cases with the description given in the GRADALL Parts Manual.

NOTE !

Form No. 29635 3/97

To check GRADALL torque values, set the torque wrench at the minimum rated torque value and tighten fastener. If the torque wrench releases before the fastener moves, assume that the fastener torque is correct.

27


X. Miscellaneous (continued) TABLE 13 BOLT TORQUE VALUES FOR METRIC FASTENERS

Form No. 29635 3/97

28

X. Miscellaneous (continued) TABLE 14 BOLT TORQUE VALUES AND TOLERANCES FOR LUBRICATED ENGLISH BOLTS

NOTE!

Form No. 29635 3/97

“Never-seez” to be used on master link pin before assembly torque pad bolts over master link to 185 ft. lb. +10 -0

29


X. Miscellaneous (continued) Hydraulic Hose and Hose Fitting Torque Charts To minimize leakage, the hydraulic hoses and hydraulic hose fittings are torqued to specified values. Whenever a hose or fitting is removed, it should be retorqued to the correct value when it is replaced. Refer to the hydraulic hose and hydraulic fitting torque charts (Table 15, Table 16 and Table 17) for correct values used on the GRADALL product line. TABLE 16

TABLE 15

*Torque values with an asterisk are from JIC Fitting Torque Chart.

TABLE 17 ORS FACE SEAL TUBE/HOSE TO FITTING

Form No. 29635 3/97

30

X. Miscellaneous (continued) Tools Standard heavy equipment maintenance tools are required to work on the GRADALL XL SERIES CRAWLER UNDERCARRIAGE. Torque wrenches capable of achieving rated fastener values, wrenches for metric bolts and English S.A.E. bolts must be available. Large and small calipers, straight edges, steel measuring tape and a depth gauge are required for component wear measurement. Miscellaneous tools such as “come-a-long”, large” “C” clamps, etc. may also be required for some repairs. A grease fun and other tools GRADALL determines “unique” and necessary for good maintenance are furnished in the tool kit supplied with each machine.

Form No. 29635 3/97

31


Electric Drives and Controls

Hydraulics

Linear Motion and Assembly Technologies

Pneumatics

Verstellpumpe A11VO/A11VLO Variable Pump A11VO/A11VLO Baureihe / Series 11 NG / Size 190 – 260

Reparaturanleitung / Repair Manual Baugruppen / Assembly Groups

Service

RDE 92500-21-R/07.07

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Bosch Rexroth AG

Reparaturanleitung/Repair Manual A11VO / A11VLO

RDE 92500-21-R/07.07

Vermeidung von Gefahren

Avoiding Dangers

Für einen sicheren Betrieb und um Schäden bei der Reparatur zu vermeiden, lesen Sie diese Reparaturanleitung sorgfältig und aufmerksam durch!

To ensure safe operations and avoid damages during repairs, read this repair manual carefully and attentively.

Für Personen- oder Maschinenschäden, die durch Nichtbeachtung dieser Reparaturanleitung entstehen, verfällt jegliche Gewährleistung der Bosch Rexroth AG.

Bosch Rexroth AG accepts no responsibility for personal injuries or damages to the machine that arise from disregarding this repair manual.

1

1

Zu dieser Anleitung

Diese Anleitung unterstützt Sie bei der Reparatur und der Wiederinbetriebnahme von Rexroth A11VO/A11VLO Verstellpumpen Diese Anleitung umfasst die folgenden Kapitel: •

•

•

•

„Sicherheit“ auf Seite 7 Hier erhalten Sie grundsätzliche Hinweise zum sicheren Umgang mit Verstellpumpen und zu deren Betrieb. Lesen Sie dieses Kapitel, bevor Sie anfangen zu arbeiten. „Produktbeschreibung“ auf Seite 11 Hier erfahren Sie, wie Sie den Typ einer Verstellpumpe feststellen. Ferner finden Sie hier eine Übersicht über die Funktionsweise und Informationen zur bestimmungsgemäßen Verwendung der Pumpe Lesen Sie dieses Kapitel, um Ihr Grundwissen über Verstellpumpen aufzufrischen. „Austausch von Baugruppen“ auf Seite 15 Rexroth stellt verschieden Reparatursätze zur Verfügung. Dieses Kapitel erklärt Ihnen, wie Sie Dichtungen und Baugruppen einer Verstellpumpe austauschen. „Funktionsprüfungen“ auf Seite 25 Hier erfahren Sie, wie Sie die Funktion einer Rexroth A11V(L)O Verstellpumpe mit LRDS-Regler überprüfen können.

About this Manual

This manual supports you in the repair, adjustment and recommissioning of Rexroth A11VO/A11VLO variable pumps. The manual is structured as follows: •

•

•

•

“Safety” on page 7 This chapter provides you with basic hints and tips regarding working with and operating variable pumps. Read this chapter before you start working. “Product Description” on page 11 This chapter explains how you identify the fvariable pump. Additionally, it provides you an overview about how the variable pump works and information regarding the correct usage. Read this chapter to refresh your knowledge of the variable pumps. “Exchanging Subassemblies” on page 15 Rexroth provides various replacement parts for repairs. This section explains, how you exchange seals and components of a variable pump. “Functional Checks” on page 25 This chapter explains how you check the proper function of a Rexroth A11V(L)O variable pump with LRDS regulator.

RDE 92500-21-R/07.07


1.1 Inhalt

1

Zu dieser Anleitung

Bosch Rexroth AG

3/32

1.1 Content

2

1

1.1 Inhalt

3

1.1 Content

3

1.2 Gültigkeitsbereich dieser Anleitung

4

1.2 Validity of this Manual

4

1.3 Wichtige Unterlagen

5

1.3 Important Documents

5

1.4 Gefahrenkennzeichnungen und Piktogramme

6

1.4 Danger Labels and Pictograms

6

2

7

2

7

7

2.1 Basic Safety Information

Sicherheit

2.1 Grundlegende Sicherheitshinweise

About this Manual

Safety

2

7

2.2 Anforderungen an das Personal

10

2.2 Requirements on the Personnel

10

3

11

3

11

3.1 Typschild

11

3.1 Name Plate

11

3.2 Funktionsbeschreibung

11

3.2 Functional Description

11

3.3 Technische Daten

13

3.3 Technical Data

13

4

15

4

15

4.1 Triebwelle abdichten

16

4.1 Sealing the Drive Shaft

16

4.2 Reglergehäuse abdichten

19

4.2 Sealing the Control Unit Housing

19

4.3 Dichtungen austauschen

22

4.3 Replacing Seals

22

5

25

5

25

5.1 Vorbereitungen

25

5.1 Preparations

25

5.2 Prüfung des Load-Sensing Reglers (S)

26

5.2 Checking the Load-Sensing Control (S)

26

5.3 Prüfung des Leistungsreglers (LR)

27

5.3 Checking the Power Control (LR)

27

5.4 Prüfung des Druckreglers (D)

29

5.4 Checking the Pressure Control (D)

29

Produktbeschreibung

Austausch externer Baugruppen

Funktionsprüfungen

Product Description

Exchanging External Assembly Groups

Functional Checks

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Bosch Rexroth AG

1.2

Gültigkeitsbereich dieser Anleitung


1.2

RDE 92500-21-R/07.07

Validity of this Manual

Diese Reparaturanleitung gilt für die Verstellpumpen A11VO/ A11VLO der Bosch Rexroth AG. Informationen zu zugelassenen Druckflüssigkeiten entnehmen Sie den Angaben des Anlagenherstellers.

This manual is valid for the Bosch Rexroth variable pumps A11VO/A11VLO. Refer to the system manufacturer for information about the allowed hydraulic fluids.

Diese Reparaturanleitung richtet sich an folgende Zielgruppen:

This repair manual is directed at:

• • •

Anlagenbetreiber autorisierte Fachbetriebe bzw. Händler Anlagenhersteller Für den Anlagenhersteller sind zusätzlich auch die jeweilige Einbauzeichnung, das technische Datenblatt, die Betriebsanleitung und die Auftragsbestätigung der Bosch Rexroth AG verbindlich.

the system operator • authorized dealers • the system manufacturer For the system manufacturer, the installation drawing, the catalog sheet, the manual, and the confirmation of order from the Bosch Rexroth AG are also obligatory. •

RDE 92500-21-R/07.07

1.3


Wichtige Unterlagen

Bevor Sie mit den in dieser Anleitung beschriebenen Arbeiten anfangen, stellen Sie sicher, dass Sie folgende Unterlagen griffbereit haben: •

Auftragsbestätigung

1.3

Einbauzeichnung

•

Technisches Datenblatt

•

Gesamtschaltplan der Maschine bzw. Anlage

•

RD 90300-B: Allgemeine Betriebsanleitung für Verstellpumpen

•

Produktspezifische Betriebsanleitung

•

•

RD 90220: Druckflüssigkeiten auf Mineralölbasis

•

RD 90221: Umweltfreundliche Druckflüssigkeiten HEES, HEPG, HETG für Verstellpumpen

RD 90223: Verstellpumpen für den Betrieb mit HFDruckflüssigkeiten

•

RD 90300-03-B: Hinweise zum Einsatz von hydraulischen Antrieben bei tiefen Temperaturen

RE 90220: Mineral-oil Based Pressure Fluids

This publication describes the requirements on a hydraulic fluid based on mineral oil for operation in an variable pump and supports you in the selection of a hydraulic fluid for your system. •

RE 90221: Environmentally Acceptable Hydraulic Fluids HEES, HEPG, HETG for Variable Pumps

This publication describes the demands on environmentally compatible, readily biodegradeable hydraulic fluids H ETG, HEPG, HEES that can be used in Rexroth variable pumps and supports you by the selection of a hydraulic fluid for your system. •

Diese Druckschrift enthält zusätzliche Informationen zum Einsatz von Rexroth-Verstellpumpen mit HF-Druckflüssigkeiten. •

Product Specific Manual

The following Rexroth publications provide additional information to the installation and operation of variable pumps:

Diese Druckschrift beschreibt die Anforderungen an eine umweltfreundliche Druckflüssigkeit für den Betrieb mit Rexroth-Verstellpumpen und unterstützt Sie bei der Wahl einer Druckflüssigkeit für Ihre Anlage. •

RE 90300-B: General Manual for Variable Pumps

The product-specific manual contains specific information designed for the variable pump. Get in touch with Rexroth to find out if there is any product-specific information on your variable pump.

Diese Druckschrift beschreibt die Anforderungen an eine Druckflüssigkeit auf Mineralölbasis für den Betrieb in Rexroth-Verstellpumpen und unterstützt Sie bei der Wahl einer Druckflüssigkeit für Ihre Anlage. •

Hydraulic Diagram / Wiring Diagram

The general manual supports you during the installation, initiation, and operation of Rexroth variable pumps.

Die produktspezifische Betriebsanleitung enthält spezielle, für die Verstellpumpe gültige Informationen. Informieren Sie sich bei Rexroth, ob es zu Ihrer Verstellpumpe eine produktspezifische Betriebsanleitung gibt. Folgende Rexroth-Druckschriften geben Ihnen weitere Informationen zu Installation und Betrieb der Verstellpumpe:

Technical Data Sheet

The hydraulic diagram and the wiring diagram of the unit or system contain the information related to the hydraulic or electric connections. You need this data to work with the axial piston as part of the unit or system. You can get this information from the unit or system manufacturer.

Die allgemeine Betriebsanleitung unterstützt Sie bei Installation, Inbetriebnahme und Betrieb von Rexroth-Verstellpumpen. •

Installation Drawing

The technical data sheets RE 92500 contain the maximum allowed technical data for the variable pumps and further information.

Der Hydraulikschaltplan und der elektrische Schaltplan der Maschine bzw. Anlage enthalten die Informationen zu den hydraulischen bzw. elektrischen Anschlüssen. Diese Daten brauchen Sie, um mit der Verstellpumpe als Teil der Maschine bzw. Anlage zu arbeiten. Die Unterlagen erhalten Sie vom Maschinen- bzw. Anlagenhersteller. •

Confirmation of Order

The installation drawing of the variable pump contains the sizes, all connections and the wiring diagram.

Die technischen Datenblätter RD 92500 enthalten u. a. die zulässigen technischen Daten für die Verstellpumpen. •

Important Documents

The confirmation of order contains the values set during the commissioning by Rexroth. The variable pump may only be operated with the values and conditions specified in the confirmation of order.

Die Einbauzeichnung der Verstellpumpe enthält die Außenabmessungen, sämtliche Anschlüsse und den Schaltplan. •

5/32

Before you start any of the procedures described in this manual, make sure you have the following documents ready to hand:

Die Auftragsbestätigung enthält die voreingestellten technischen Daten. Die Verstellpumpe darf nur unter den i n der Auftragsbestätigung angegebenen Werten und Bedingungen betrieben werden. •

Bosch Rexroth AG

RE 90223: Variable Pumps for Use with HF Fluids

This publication provides additional information for the use of Rexroth variable pumps with HF hydraulic fluids. •

RE 90300-03-B: Instructions on the Use of Hydrostatic Drives at Low Temperatures

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1.4

Bosch Rexroth AG


Gefahrenkennzeichnungen und Piktogramme

Diese Anleitung unterscheidet zwischen Kategorien von Gefahren gemäß ISO Guide 37: ! GEFAHR Weist auf hohes Risiko und die Gefahr von Tod oder schweren Verletzungen hin.

! WARNUNG Weist auf mittleres Risiko und die Gefahr von Verletzungen und schweren Sachschäden hin.

! VORSICHT Weist auf geringes Risiko und Sachschäden hin.

Hinweis Kennzeichnet Informationen, die zum besseren Verständnis der Maschinenabläufe beitragen oder weist auf einen besonderen bzw. wichtigen Sachverhalt hin.

Tipp Kennzeichnet Informationen, die zum effizienteren Arbeiten beitragen.

1.4

RDE 92500-21-R/07.07

Danger Labels and Pictograms

This manual differentiates between the following categories of hazards, according to ISO Guide 37: ! DANGER Indicates high risk, mortal danger and serious injuries.

! WARNING Indicates middle risk, injuries or serious material damage.

! CAUTION Indicates low risk or material damage.

Note Indicates information that contributes to a better understanding of the machine processes or indicates important information.

Tip Indicates information that contributes to more efficient work.

RDE 92500-21-R/07.07

2


Sicherheit

2

Bosch Rexroth AG

7/32

Safety

Lesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbeiten an der Verstellpumpe beginnen.

Read through this chapter carefully before you start any work on the variable pump.

Die Rexroth-Verstellpumpen sind im Sinne der Maschinenrichtlinie 98/37/EG Komponenten, die zum Einbau in eine Anlage bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung beziehen sich nur auf die Verstellpumpe. Beachten Sie zusätzlich die Sicherheitsrichtlinien des Anlagenherstellers.

The Rexroth variable pumps are in the sense of the machine guideline 98/37/EG components of a system. The safety guidelines in this manual only cover the variable pump. You must additionally follow the system manufacturer’s safety guidelines.

Informieren Sie sich an Hand der allgemeinen Betriebsanleitung für Verstellpumpen über die bestimmungsgemäße Verwendung und die Sorgfaltspflicht des Betreibers und Bedieners.

Read the general manual for variable pump units to get more information on the designated use and the operator‘s obligation to exercise diligence.

2.1

2.1

Grundlegende Sicherheitshinweise

Befolgen Sie die folgenden Sicherheitshinweise und die des Anlagenherstellers genau, um Verletzungen und Gesundheitsschäden sowie Sach- und Umweltschäden auszuschließen.

Basic Safety Information

Pay attention to the following safety information and that of the system manufacturer to eliminate injuries and health damages as well as damages to material or the environment.

! GEFAHR

! DANGER

Lebensgefahr

Danger to life

Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen stellt eine Gefahr für Leib und Leben dar.

Working on systems that have not been shut down completely is life-threatening.

Die in diesem Dokument beschriebenen Arbeiten dürfen nur an stillgelegten Maschinen bzw. Anlagen vorgenommen werden. Bevor Sie mit den Arbeiten beginnen:

The work described in this document must only be carried out on a shut down system. Before you start any of the tasks:

•

•

•

Stellen Sie sicher, dass der Antriebsmotor nicht eingeschaltet werden kann. Stellen Sie sicher, dass sämtliche kraftübertragenden Komponenten und Anschlüsse (elektrisch, pneumatisch, hydraulisch) gemäß den Herstellerangaben ausgeschaltet sind und nicht eingeschaltet werden können. Falls möglich, entfernen Sie die Hauptsicherung der Maschine bzw. Anlage. Stellen Sie sicher, dass die Maschine bzw. Anlage komplett hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den Angaben des Maschinen- bzw. Anlagenherstellers.

•

Make sure that the motor cannot be switched on.

•

Make sure that all components and connections that carry energy (electrical, pneumatic, hydraulic) have been shut down according to the manufacturer’s instructions and cannot be switched on. If possible, remove the main fuse.

•

Make sure that the system is completely unpressurized. Follow the instructions of the system manufacturer.

! WARNUNG

! WARNING

Verletzungsgefahr

Danger of injury

Um Verletzungen zu vermeiden, beachten Sie bitte folgende Empfehlungen betreffend Sicherheitskleidung:

To avoid injuries, pay attention to the following recommendations regarding safety clothing:

•

•

Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicherheitsschuhe mit Stahlkappen. Tragen Sie bei Arbeiten mit gefährlichen Stoffen (beispielsweise Druckflüssigkeiten) Schutzhandschuhe und Schutzbrille.

•

When working on the system, wear steel-toed s afety shoes.

•

When working with dangerous substances (for example, certain hydraulic fluids), wear protective gloves and protective glasses.

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Bosch Rexroth AG


! GEFAHR

RDE 92500-21-R/07.07

! DANGER

Vergiftungs- und Verletzungsgefahr

Danger of poisoning or injury

Der Kontakt mit Druckflüssigkeiten ruft Gesundheitsschäden hervor (z.B. Augenverletzungen, Haut- und Gewebeschädigungen, Vergiftungen beim Einatmen).

Contact with hydraulic fluids can cause health damage (e. g. eye injuries, skin and tissue damage, poisoning due to inhalation).

•

•

•

•

Überprüfen Sie vor jeder Inbetriebnahme die Leitungen auf Verschleiß bzw. Beschädigungen. Tragen Sie dabei Schutzhandschuhe und Schutzbrille.

•

Wenn dennoch Druckflüssigkeit in die Augen gelangt oder in die Haut eindringt, konsultieren Sie unmittelbar einen Arzt. Beachten Sie beim Umgang mit Druckflüssigkeiten unbedingt die Sicherheitsangaben des Druckflüssigkeitsherstellers.

•

•

•

! WARNUNG

Always check the hydraulic lines for wear and damage prior to putting the unit into operation. When checking the lines, wear protective gloves and safety glasses. Should pressure fluid come into contact with your eyes or skin: Get medical help immediately! When handling hydraulic fluids, pay attention to the hydraulic fluid manufacturer’s safety instructions.

! WARNING

Verbrennungsgefahr

Danger of burns

Die Verstellpumpe erwärmt sich während des Betriebs. Auch die Magnete an der Verstellpumpe werden im laufenden Betrieb heiß. Finger und Hände können bei Berührung der Verstellpumpe oder der Magnete schwere Brandverletzungen erleiden.

The variable pump heats up during operation. The unit’s solenoids get hot during operation. Fingers and hands can be badly burned when touching the variable pump or solenoids.

• •

Lassen Sie die Verstellpumpe vor jedem Kontakt abkühlen. Schützen Sie sich mit hitzebeständigen Handschuhen und Schutzkleidung.

• •

! GEFAHR

Let the variable pump cool down prior to any contact. Protect yourself from burns by wearing safety gloves and protective clothing.

! DANGER

Vergiftungs- und Verletzungsgefahr

Danger of poisoning and injuries

Beim Suchen nach Leckstellen kann entweichende Druckflüssigkeit in die Haut eindringen und schwerste Vergiftungen und Verletzungen hervorrufen.

When looking for leaks, escaping hydraulic fluid can break into the skin and cause serious poisoning and injuries.

•

Suchen Sie nur bei abgestellter und druckloser Maschine nach Leckstellen.

•

! WARNUNG

Look only for leaks, if the variable pump unit is shut down and unpressurized.

! WARNING

Verletzungs- und Beschädigungsgefahr

Danger of injuries or damage

Durch falsch angeschlossene Komponenten können erhebliche Fehlfunktionen entstehen.

Incorrectly connected components can considerably impair the functionality of a hydraulic system.

•

Achten Sie auf korrekte Verrohrung gemäß Schaltplan.

•

•

Führen Sie komponentenorientierte Funktionstests durch.

•

Make sure that the hydraulic lines are connected properly according to the wiring diagram. Check the correct functioning of all components.

RDE 92500-21-R/07.07


! GEFAHR

Danger of fire

Hydraulische Druckflüssigkeit ist brennbar.

Hydraulic fluid is inflammable.

Halten Sie offenes Feuer und Zündquellen von der Verstellpumpe fern.

9/32

! DANGER

Feuergefahr

•

Bosch Rexroth AG

•

! WARNUNG

Keep open fires and ignition sources away from the variable pump.

! WARNING

Gehörschäden

Danger of hearing damage

Die Geräuschemission von Verstellpumpen ist u.a. von Drehzahl, Betriebsdruck und Einbauverhältnissen abhängig. Es ist damit zu rechnen, dass der Schalldruckpegel bei normalen Einsatzbedingungen über 70 dBA steigt. Dies kann zu Gehörschäden führen.

The noise emission produced by variable pump units depends on speed, operating pressure, and installation. During normal application conditions, over 70 dBA can be anticipated. This can lead to hearing damage.

•

Schützen Sie sich stets mit Gehörschutz bei Arbeiten in der Nähe der Verstellpumpe während des laufenden Betriebs.

•

! WARNUNG

Always wear hearing protection when working in the vicinity of the variable pump during operation.

! WARNING

Umweltschäden

Risk of damage to the environment

Druckflüssigkeiten sind wassergefährdende Flüssigkeiten. Das Austreten von Druckflüssigkeiten kann zu Grundwasservergiftung und Bodenverseuchung führen.

Hydraulic fluid is hazardous to waters. Hydraulic fluid leakage leads to contamination of the ground and ground water.

•

Bringen Sie unter der Verstellpumpe eine Auffangwanne an.

•

•

Beseitigen Sie Leckstellen unverzüglich. Es sind stets die nationalen Gesetze und Vorschriften zu beachten. In Deutschland sind hydraulische Maschinen bzw. Anlagen „Anlagen zum Umgang mit wassergefährdenden Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG)“. Beachten Sie in diesem Zusammenhang besonders §1 und §19 WHG (§19g, 19i, 19l). Weitere Informationen finden Sie in den RexrothDruckschriften „Druckflüssigkeiten auf Mineralölbasis“, RD 90 220, „Umweltschonende, biologisch schnell abbaubare Druckflüssigkeiten HEPG, HEES für Axialkolbenmaschinen“, RD 90 221-1 und „Axialkolbenmaschinen für den Betrieb mit HF-Druckflüssigkeiten, RD 90 223.

•

•

•

•

•

A basin for catching any hydraulic fluid must be placed under the variable pump. Leaks must be cleaned up immediately. Pay always attention to any national regulations and norms. In Europe, hydraulic systems are considered “Systems using water-threatening substances” in the sense of the Water Management Law (WHG).Therefore, pay special attention to §1 and §19 WHG (§19g, 19i, 19l). Further information is available in the Rexroth publications „Mineral-oil based hydraulic fluids“, RE 90 220. „Environmentally acceptable, rapid biologically degradable hydraulic fluids HEPG, HEES for axial piston units“, RE 90 221-1 and „Axial piston units for operation with HF hydraulic fluids, RE 90 223.

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Bosch Rexroth AG

2.2

Anforderungen an das Personal


2.2

RDE 92500-21-R/07.07

Requirements on the Personnel

Diese Reparaturanleitung richtet sich an Fachkräfte mit Hydraulik-Fachwissen, die an einer Service-Schulung bei Rexroth teilgenommen haben.

This repair manual is directed at qualified personnel with specialized hydraulics know-how who have taken part at a service training at Rexroth.

Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung und Erfahrung ausreichende Kenntnisse hat, sowie mit den einschlägigen Bestimmungen so weit vertraut ist, dass er

Qualified personnel is defined as persons who have sufficient

• • •

•

•

die ihm übertragenenen Arbeiten beurteilen kann, mögliche Gefahren erkennen kann, die notwendigen Maßnahmen zur Beseitigung von Gefahren ergreifen kann, Kenntnisse über die möglichen Gesundheitsgefahren von Druckflüssigkeiten hat und die erforderlichen Reparatur- und Montagekenntnisse hat.

Hydraulik-Fachwissen bedeutet, das Personal muss

knowledge on the basis of specialized training and experience, and are familiar with the relevant regulations, so that they are able to • judge

•

the delegated tasks, recognize possible dangers, take the necessary measures for the elimination of dangers,

•

know the possible health risks from hydraulic fluids,

•

and have the required repair and installation know-how.

•

Specialized hydraulics know-how means that the personnel

must: •

•

•

in der Lage sein, die Hydraulikpläne zu lesen und vollständig zu verstehen, insbesondere die Zusammenhänge bezüglich der eingebauten Sicherheitseinrichtungen vollständig verstehen und Kenntnisse über Funktion und Aufbau von hydraulischen Bauteilen haben.

•

be able to read and completely understand hydraulic plans

•

especially understand completely the coherences regarding the installed safety equipment be familiar with the function and structure of hydraulic components.

•

RDE 92500-21-R/07.07

3

Bosch Rexroth AG


Produktbeschreibung

3

11/32

Product Description

Dieses Kapitel gibt Ihnen einen allgemeinen Überblick über die Funktionalität der Rexroth A11VO/A11VLO Verstellpumpen.

This chapter provides a general overview of the functionality of the A11VO/A11VLO variable displacement pumps.

Machen Sie sich mit den Inhalten dieses Kapitels vertraut, bevor Sie mit Arbeiten an einer Verstellpumpe beginnen.

You should be familiar with the contents of this chapter before starting any work on the variable displacement pump.

3.1

3.1

Typschild

Die Verstellpumpe ist am Typschild zu identifizieren (Beispiel):

Name Plate

The variable displacement pump can be identified on its type plate (example):

Rexroth

1

D-89275 Elchingen 2 3

TYP: A11VLO190LRDS/10R-NZD12N00 MNR: R90XXXXXXX

4

SN:

12345678

FD:

07W09

5 6

7202 Rotation:

n = XXXX min-1

7 8

9

p = XXX kW 10

Made in Germany

Folgende Informationen finden Sie auf dem Typschild:

The following information can be found on the type plate:

1 Hersteller

1 Manufacturer

2 Typschlüssel

2 Ordering code

3 Materialnummer der Axialkolbenmaschine

3 Material number of the axial piston unit

4 Seriennummer

4 Serial number

5 Fertigungsdatum

5 Date of manufacturing

6 Drehzahl

6 Speed

7 interne Werksbezeichnung

7 Internal manufacturing code

8 Drehrichtung (bei Blick auf die Welle; hier: im Uhrzeiger-

8 Direction of rotation (when facing the shaft; here: clockwi-

sinn) 9 Vorgesehener Platz für Prüfstempel 10 Leistung Stellen Sie sicher, dass Typ und Nenngröße der zu reparierenden Verstellpumpe mit dieser Anleitung übereinstimmen.

se) 9 Designated space for certification stamp 10 Power Ensure that the variable displacement pump to be repaired is of the type and size covered by this manual.

3.2

3.2

Funktionsbeschreibung

Functional Description

Damit Sie in der Lage sind, Probleme an der Verstellpumpe zu identifizieren und gezielt Reparaturen durchzuführen, sind Kenntnisse der Funktionsweise und des Aufbaus erforderlich. Dieser Abschnitt gibt Ihnen eine grobe Übersicht.

To make sure that you are able to identify problems with a variable displacement pump and to carry out specific repairs, familiarity with how the unit functions and its assembly are required. This section provides you with a rough overview.

Die A11VO/A11VLO Verstellpumpen sind Axialkolben-Verstellpumpe in Schrägscheibenbauart für hydrostatische Antriebe im offenen Kreislauf. Der Volumenstrom ist proportional zu der Antriebsdrehzahl und dem Verdrängungsvolumen. Durch die Verstellung der Schrägscheibe ist eine stufenlose Volumenstromänderung möglich.

The variable displacement axial piston pumps type A11VO/ A11VLO in swashplate design are designed for open circuit hydrostatic drives. The flow is proportional to the input drive speed and displacement. By adjusting the swashplate, it is possible to infinitely vary the flow.

A11VLO Pumpen haben einen eingebauten Impeller (Ladepumpe). Das ist eine Kreiselpumpe, die es erlaubt, die Pumpen mit höheren Drehzahlen zu betreiben.

A11VLO pumps have a built-in impeller. This is a turbo pump that makes it possible to increase the rotational speed for driving the pumps.

12/32

Bosch Rexroth AG


RDE 92500-21-R/07.07

Schnittzeichnungen

Sectional Drawings

Die folgenden Schnittzeichnungen zeigen den Aufbau der A11VO/A11VLO Verstellpumpe.

The following drawings show the design of the A11VO/ A11VLO variable displacement pump.

A11VLO 190, 260 LRDS

Qmin Stop

Triebwerk / Rotary Unit

Regler / Control Unit

Antriebswelle / Drive Shaft

Verschlussring mit Wellendichtring / Cover Ring with Shaft Seal

Ladepumpe / Impeller

Qmax Stop

Qmin Stop / Qmax Stop: Anschlag für minimalen/maximalen Schwenkwinkel.

Qmin Stop / Qmax Stop: Stop for minimum/maximum swivel angle.

Reglerbeispiele / Control Unit Examples

LRDS

DRS

LRDH

RDE 92500-21-R/07.07


Bosch Rexroth AG

13/32

EP

Leistungsregler D, DR: Druckregler Load-Sensing S: EP: Elektrische Verstellung Hydraulische Verstellung HD: LR:

3.3

Technische Daten

Die technischen Daten der Verstellpumpe finden Sie in der Auftragbestätigung. Ergänzend dazu ist das jeweilige technische Datenblatt. Für die A11VO/A11VLO Verstellpumpe gilt das technische Datenblatt RD 92500.

Power Control Pressure Control Load-Sensing Control Electrical Control Hydraulic Control

3.3

Technical Data

You can find the technical data for the variable displacement pump in the Confirmation of Order. This is supplemented by the unit‘s data sheet. For the A11VO/A11VLO variable displacement pump, the valid data sheet is RE 92500.

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Bosch Rexroth AG


RDE 92500-21-R/07.07

RDE 92500-21-R/07.07

4


Austausch externer Baugruppen

4

Bosch Rexroth AG

15/32

Exchanging External Assembly Groups

Dieses Kapitel beschreibt den Austausch von Baugruppen und Dichtungen der Verstellpumpen A11VO/A11VLO.

This chapter describes the replacement of the externally accessible assembly groups and sealings of the variable pumps A11VO/A11VLO.

Der Austausch von Dichtungen folgender Baugruppen wird beschrieben:

The exchange of sealings of the following a ssembly groups is described:

• • •

Triebwelle Regler Dichtmuttern

• • •

! WARNUNG

Drive shaft Control unit Seal Locks ! WARNING

Gefahr von Verschleiß und Funktionsstörungen

Danger of wear and malfunction

Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der Hydraulikanlage stehen in unmittelbarem Zusammenhang. Verschmutzung der Druckflüssigkeit führt zu Verschleiß und Funktionsstörungen. Insbesondere harte Fremdkörper in den Hydraulikleitungen, wie z.B. Schweißperlen und Metallspäne, beschädigen die Axialkolbenmaschine.

The durability of the hydraulic unit depends to a great extent on how clean the unit is kept. Dirt in the hydraulic fluid can lead to malfunctions. Especially hard foreign matter in the hydraulic lines, for example, welding beads and metal cuttings, will definitely damage the axial piston unit.

Beachten Sie daher unbedingt folgende Hinweise:

Therefore you should observe the following instructions:

•

•

•

•

•

Achten Sie auf äußerste Sauberkeit. Die Axialkolbenmaschine muss schmutzfrei eingebaut werden. Verunreinigungen in der Druckflüssigkeit können die Funktion und Lebensdauer der Axialkolbenmaschine erheblich beeinträchtigen. Achten Sie besonders bei der Installation darauf, dass Anschlüsse, Hydraulikleitungen und Anbauteile ( z.B. Messgeräte) sauber sind. Reinigen Sie diese gründlich, bevor Sie Anschlüsse öffnen. Stellen Sie sicher, dass auch beim nachfolgenden Verschließen der Anschlüsse keine Verunreinigungen eindringen. Verwenden Sie für die Beseitigung von Schmiermitteln und anderen starken Verschmutzungen geeignete flüssige Reinigungsmittel. Es darf kein Reinigungsmittel in das Hydrauliksystem eindringen. Verwenden Sie zur Reinigung keine Putzwolle oder fasernde Putzlappen. Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder Kitt.

•

•

•

Make sure everything is kept extremely clean. The axial piston unit must be installed in a dirt-free environment. Contamination of the hydraulic fluid can lead to considerable wear and malfunctions of the axial piston unit. Especially during the installation, you should make sure that ports, hydraulic conduits, and mounting components (for example, gauges) are clean. Clean these thoroughly before you open connections. After that, when sealing the ports, make sure that contaminating elements cannot enter the system. When removing grease and other dirt you should use appropriate liquid cleaning agents. Cleaning agents must not enter the hydraulic system.

•

Do not use cotton waste or rags which lose threads.

•

Never use hemp or putty as a sealant.

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Bosch Rexroth AG

4.1

Triebwelle abdichten


4.1

RDE 92500-21-R/07.07

Sealing the Drive Shaft

Dieser Abschnitt erklärt, wie Sie die Triebwelle abdichten.

This section explains how you seal the drive shaft.

Benötigtes Sonderwerkzeug:

Required Special Tools:

•

Montagebüchse Die Materialnummern sind je nach Pumpenmodell verschieden: A11VO/A11VLO – NG 190: Mat. Nr. R90450647 – NG 260: Mat. Nr. R90450941

•

Mounting sleeve The material number depends on the pump model: A11VO/A11VLO – Size 190: – Size 260:

Mat. no. R90450647 Mat. no. R90450941

e c d b a a: b: c: d: e:

Sicherungsring Verschlussring Wellendichtring O-Ring Triebwelle

Circlip Cover Ring Shaft Seal O-ring Drive Shaft

Um die Triebwelle abzudichten:

To seal the drive shaft:

1 Kleben Sie die Triebwelle (e) ab, um Beschädigungen bei

1 Mask the drive shaft (e) for damage protection while repla-

der Montage des neuen Wellendichtrings zu vermeiden.

cing the shaft seal. e

RDE 92500-21-R/07.07

Bosch Rexroth AG


2 Entfernen Sie den Sicherungsring (a).

17/32

2 Remove the circlip (a).

a

3 Drücken Sie den Verschlussring (b) ab.

3 Press off the cover ring (b).

Damit entfernen Sie auch den Wellendichtring, der in den Verschlussring eingepresst ist

This action removes also the shaft seal that is pressed into the cover ring. b

4 Entfernen Sie den Wellendichtring (c) aus dem Verschluss-

ring (b) sowie den O-Ring (d) aus dem Gehäuse. Kontrollieren Sie den Verschlussring (b), die Triebwelle (e) und das Gehäuse (f) auf Verschleiß und Verunreinigungen.

4 Remove the shaft seal (c) from the cover ring (b) and the

o-ring (d) from the housing. Check the cover ring (b), the drive shaft (e), and the housing (f) for wear and dirt. e f d

b

c

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Bosch Rexroth AG


5 Pressen Sie den Wellendichtring (c) mit Hilfe der passenden

Montagebüchse (g) (Sonderwerkzeug) lagerichtig in den Verschlussring ein.

RDE 92500-21-R/07.07

5 Using the suitable mounting bush (g) (special tool), press in

the shaft seal (c) until it is correctly orientated in the cover ring.

g

g

c

Bei tiefer Laufrille legen Sie eine Scheibe auf den Wellendichtring.

If the shaft is deeply grooved, insert a shim behind the shaft seal.

6 Fetten Sie den neuen Wellendichtring zwischen Dicht- und

6 Grease the new shaft seal between the seal and dust lips to

Staublippe leicht ein, um Trockenlauf zu vermeiden.

avoid a dry run.

7 Fetten Sie den neuen O-Ring (d) leicht ein und legen Sie ihn

in das Gehäuse (f) ein. Prüfen Sie, ob der O-Ring bündig anliegt.

7 Grease the the new o-ring (d) slightly and insert it into the

housing (f). Ensure, that it is correctly placed.

d f

8 Insert the cover ring with the shaft seal into the housing.

8 Setzen Sie den Verschlussring mit dem Wellendichtring in

das Gehäuse ein. 9 Führen Sie den Sicherungsring (a) so in das Gehäuse (f) ein,

into place in the respective slot of the cover ring.

dass er in die dafür vorgesehene Nut des Verschlussrings einrastet. Kontrollieren Sie den Sitz des Sicherungsrings in der Nut.

a

10 Entfernen Sie die Abklebung der Triebwelle.

9 Place the safety ring (a) into the housing (f) so that it locks

Check to ensure that the circlip is correctly located within the groove.

f

10 Remove the mask from the drive shaft.

RDE 92500-21-R/07.07

4.2

Bosch Rexroth AG


Reglergehäuse abdichten

4.2

Das Reglergehäuse wird mit vier O-Ringen gegen die Anschlussplatte abgedichtet.

Sealing the Control Unit Housing

Four o-rings are used to seal the regulator housing from the port plate.

b

c

d

a

a: b: c: d:

19/32

Anschlussplatte Regler O-Ringe Messkolben mit Winkelhebel

Port Plate Control Unit O-rings Measuring Piston with angled Lever

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Bosch Rexroth AG


Regler, z. B. LRDS

RDE 92500-21-R/07.07

Control Unit Example, LRDS

S D LR

LR: D: S:

Leistungsregler Druckregler Load-sensing Regler

Hinweis Einstellschrauben nicht verändern. Falls erforderlich, Gewindehülse komplett mit Einstellschrauben ausbauen.

! VORSICHT Vor dem Abschrauben eines Reglers mit Messfeder (z. B. LRDH, EP): Zuerst Steuerbuchse mit Messfeder ausbauen, dann Reglergehäuse abbauen!.

Power control Constant pressure control Load-sensing valve

Note Do not change the position of adjustment screws. If necessary, remove the complete set of threaded bush with adjustment screws.

! CAUTION Before removing a control unit with measuring spring (for example LRDH, EP): First remove the control bush with the measuring spring, then remove the regulator housing!

RDE 92500-21-R/07.07

Bosch Rexroth AG


Beispiel für einen Regler mit Messfeder

21/32

Example of a Control Unit with Measuring Spring

EP

Ausbauen / Remove

Um den Regler abzudichten:

To seal the control unit:

1 Entfernen Sie die fünf Befestigungsschrauben.

1 Remove the five fixing screws.

2 Drücken Sie den Regler ab.

2 Press off the control unit.

! VORSICHT

! CAUTION

Dichtfläche nicht beschädigen!

Make sure that the sealing surface is not damaged!

3 Legen Sie vier neue O-Ringe in die Anschlussplatte ein.

3 Insert four new o-rings into the grooves of the port plate.

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Bosch Rexroth AG


4 Achten Sie vor dem Aufsetzen des Reglers auf die korrekte

Positionierung von Messkolben und Winkelhebel (d).

RDE 92500-21-R/07.07

4 Before mounting the regulator ensure that the measuring

piston and angled lever (d) are correctly positioned.

d

5 Ziehen Sie die fünf Befestigungsschrauben an.

5 Insert and tighten the five fixing screws

4.3

4.3

Dichtungen austauschen

Replacing Seals

Dieser Abschnitt erklärt, wie Sie die Dichtmuttern ersetzen.

This section explains how you replace the seal nuts.

Benötigtes Sonderwerkzeug: Keines

Required special tools: None

Um eine Dichtmutter auszutauschen:

To replace a seal nut:

1 Messen und notieren Sie das Maß X für die spätere Montage

1 Measure and write down the dimension X of the seal nut (a).

der Dichtmutter (a). Entfernen Sie die Dichtmutter.

You need this for the subsequent assembly. Remove the seal nut.

a X

2 Schrauben Sie die neue Dichtmutter (a) ein. Blockieren Sie

die Stellschraube (b) während Sie die Dichtmutter festziehen. Kontrollieren Sie das Maß X nach der Montage.

2 Screw in the new seal lock (a) manually. Block the adjusting

screw (b) while you tighten the seal nut. Check the dimension X after assembly.

a b

RDE 92500-21-R/07.07


Anziehdrehmomente für Seal-Lock Dichtmuttern (nach N 02.100)

Gewinde / Thread

M6 M6 x 0,5 M8 M8 x 1 M10 M10 x 1 M12 M12 x 1,5 M14 M14 x 1,5 M16 M16 x 1,5

Bosch Rexroth AG

Tightening Torques for Seal-Lock Sealing Nuts (according to N 02.100)

Anziehdrehmoment MA in Nm Tightening torque MA in Nm

10 11 22 24 40 44 69 72 110 120 170 180

23/32

24/32

Bosch Rexroth AG


RDE 92500-21-R/07.07

RDE 92500-21-R/07.07

5

Bosch Rexroth AG


Funktionsprüfungen

5

25/32

Functional Checks

Dieses Kapitel gibt Ihnen Beispiele, wie Sie die Funktion einer Rexroth A11VO/A11VLO Verstellpumpe mit LRDS-Regler überprüfen können.

This chapter provides examples on how to check the proper function of a Rexroth A11VO/A11VLO variable pump with LRDS regulator.

5.1

5.1

Vorbereitungen

Preparations

1 Fordern Sie das Leistungsdiagramm bei Bosch Rexroth an.

1 Order the power curve diagram at Bosch Rexroth.

2 Überprüfen Sie die Drehrichtung.

2 Check the direction of rotation.

3 Bauen Sie die Pumpe ein, befestigen Sie sie, und befüllen

3 Install and fix the pump. Fill the housing.

Sie das Gehäuse.

Anschlüsse / Ports

A11VO/A11VLO 190 ... 260 LRDS X X S D LR

M

G

M1

M:

Messstelle Arbeitsanschluss Test port for pressure

M1:

Messstelle Stellkammer Leistungsregler Druckabschneidung Load-Sensing-Regler Anschluss für LS-Regler Anschluss für Fremdstelldruck

LR: D: S: X: G:

Test port for stroking cylinder Power Control Pressure Cut-off Load-Sensing Control Port for LS Control Port for externally applied control pressure

26/32

Bosch Rexroth AG

5.2

Prüfung des Load-Sensing Reglers (S)


5.2

RDE 92500-21-R/07.07

Checking the Load-Sensing Control (S)

Einstellvorgang

Setting process

1 Auf Prüftemperatur fahren

1 Heat up the system to test temperature

2 Antriebsdrehzahl einstellen

2 Set drive speed

3 Qmin Anschlag ausschrauben

3 Screw out Qmin stop

4 Verwenden Sie folgenden Testaufbau

4 Use the following test setup

Testaufbau

Test Setup

Messmotor-Volumenstrommessgerät / Measuring Motor Belastungsventil / Charge Valve

Messblende - Absperrhahn / Measuring Throttle - Locking Tap

pHD2 pdiff pHD1

Dreiwegehahn / 3-Way Tap

Anschlüsse

Connections

Dreiwegehahn / 3-Way Tap

Messblende - Absperrhahn / Measuring Throttle - Locking Tap M A,

G

X

Druckregler / Constant Pressure Control Load-Sensing-Regler / Load-Sensing Control Leistungsregler / HP-Control

S

M1

RDE 92500-21-R/07.07


Bosch Rexroth AG

27/32

Messblende/Absperrhahn Absperrhahn vorsichtig schließen schließen bis Qmax/2 5 Messblende/

5 Carefully close the measuring throttle's locking tap up to

6 pdiff am LS-Regler einstellen und kontern.

H P-control and jam the screw. 6 Set pdiff at the HP-control

Zum Beispiel: pdiff = 18 18 bar: pHD2 = 100 bar pHD1 = 118 bar schließen. 7 Dreiwegehahn in der X-Leitung vorsichtig schließen. 8 Qmin Schraube anlegen, 1/2 Umdrehung wieder herausdrehen und kontern.

For example: pdiff = 18 18 bar: pHD2 = 100 bar pHD1 = 118 bar entirely. 7 Close the measuring throttle's locking tap entirely. 1/2 rotation and jam the 8 Place Qmin screw, screw-out again 1/2 screw.

5.3

5.3

(halber Volu Volumenstrom). menstrom). Hochdruck 100 bar (pHD2) nach der Messblende (Belastungsventil) einstellen.

Prüfung des Leistungsreglers (LR)

Qmax/2 (half flow). Set high pressure 100 bar (p HD2) behind the measuring throttle (charge valve).

Checking the Power Control (LR)

Einstellvorgang

Setting process

Druckregler egler blockieren (eindrehen). 1 Druckr

1 Block constant pressure control (screw-in).

Leistungsreglerr nach Leistungsdiagramm (LD) einstellen. 2 Leistungsregle

H P diagram (power diagram). 2 Set the power control as to HP

Absperrhahn öffnen. 3 Messblende, Absperrhahn

throttle, open the locking tap. 3 At the measuring throttle,

4 Förderstrom Qmax einstellen (Qmax-Schraube).

4 Set flow to Qmax (Qmax screw).

Beispiel 1

Example 1

Einstellung des Regelbeginns über einen Punkt auf der Leistungskennlinie nach Druck und Volumen.

Setting the start of regulation at a point of the horse power diagram (pressure/flow).

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Bosch Rexroth AG


RDE 92500-21-R/07.07

Beispiel 2

Example 2

Einstellung des Regelbeginns. Druck (Stelldruck) an M 1.

Setting the start of regulation, pressure (stroking pressure) at M1.

Hinweis

Note

Diese Einstellung ist „ungenau“ (Toleranz). (Toleranz).

This setting is „unprecise“ (Tolerance).

Beispiel:

Example:

Regelbeginn = 120 bar.

Begin of regulation = 120 bar.

Betriebsdruck langsam erhöhen bis Manometer an M = 120 bar anzeigt. Ddabei darf der Stelldruck an M 1 ca. 1/3 vom Betriebsdruck, also etwa 40 bar betragen.

Slowly increase operation pressure up to pressure gauge at M = 120 bar. The positioning pressure at M 1 may be up to approx. 1/3 of the operation pressure, i.e. approx. 40 bar.

Das ist der Regelbeginn.

This is the start of the regulation.

Zum Beispiel:

For example:

Druck an M = 120 bar

Pressure at M = 120 bar

Druck an M 1 = 20 bar

Pressure at M1 = 20 bar

Regelbeginn zu spät, also Leistungsüberschreitung

Start of regulation too late, i.e. i .e. Power excess.

Einstellschraubee herausdrehen bis ca. 40 bar erreicht werden. Einstellschraub

Unscrew setting screw until approx. 40 bar are reached.

M =120 bar

M1 =40 bar

RDE 92500-21-R/07.07

5.4


Prüfung des Druckreglers (D)

5.4

Bosch Rexroth AG

29/32

Checking the Pressure Control (D)

Einstellung des Druckreglers mittels Belastungsventil nach Leistungsdiagramm.

Setting with help of the charge valve the constant pressure control as to HP diagram.

Beispiel: Druckreglereinstellung = 310 bar

Example: Setting of constant pressure control = 31 310 0 bar

Betriebsdruckk mit Belastungsventil auf ca. 350 bar erhöhen. 1 Betriebsdruc

pressure with help of charge valve to 1 Increase operation pressure approx. 350 bar.

2 Blockierten Druckregler vorsichtig herausdrehen bis 310 bar

constant pressure control carefully until 2 Unscrew blocked constant

erreicht werden. Einstellschraube be kontern. 3 Einstellschrau

310 bar are reached. 3 Jam setting screw.

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Bosch Rexroth AG


RDE 92500-21-R/07.07

RDE 92500-21-R/07.07


Bosch Rexroth AG

31/32

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Bosch Rexroth AG


RDE 92500-21-R/07.07

© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns. Die angegebenen Daten dienen allein der Produktbeschreibung. Eine Aussage über eine bestimmte Beschaffenheit oder eine Eignung für einen bestimmten Einsatzzweck kann aus unseren Angaben nicht abgeleitet werden. Die Angaben entbinden den Verwender nicht von eigenen Beurteilungen und Prüfungen. Es ist zu beachten, dass unsere Produkte einem natürlichen Verschleiß- und Alterungsprozess unterliegen. Änderungen vorbehalten.

Bosch Rexroth AG Hydraulics Produktsegment Axialkolbenmaschinen Werk Elchingen Glockeraustraße 2 89275 Elchingen, Germany Telefon +49 (0) 73 08 82-0 Telefax +49 (0) 73 08 72-74 [email protected]

© This document, as well as the data , specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

H Y13-1512-004-M 1/U S

TorqmotorTM Service Procedure

Effective:

March 2005

TC, TB, TE, TJ, TF, TG, TH and TL Series Low Speed, High Torque Hydraulic TorqmotorsTM

HY13-1512-004-M1/USA

Torqmotor™ Service Ser vice Procedure TC,TB,, TE, TJ, TF, TC,TB TF, TG, TH and TL Serie Series s

WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by Parker Hannifin Corporation and its subsidiaries at any time without notice.

Offer of Sale The items described in this document are hereby offered for sale by Parker Hannifin Corporation, its subsidiaries or its authorized distributors. This offer and its acceptance are governed by the provisions stated in the "Offer of Sale". ©

Copyright 2005, 2000, 1999, Parker Hannifin Corporation, All Rights Reserved

2

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 37745 US

Torqmotor™ Service Ser vice Procedure TC,TB, TC,T B, TE, TJ, TF, TF, TG, TH and TL Serie Series s

HY13-1512-004-M1/USA

Table of Contents

Definitions Definit ions .............. ............................... ................................. ................................ ................................. ................................. ................................. ................................. ................................. .............................. .............3 3 Design Feature Features s ................ ................................. ................................. ................................ ................................. ................................. ................................ ................................ ...............................4 ...............4 - 5 Introduction Introd uction ................ ................................ ................................. ................................. ................................. ................................. ................................ ................................ ................................. ........................... .......... 7 Troub roubleshoo leshooting ting Guide ............... ................................ ................................. ................................. ................................. ................................ ................................. ................................. ........................... ........... 8 Troubles roubleshooting hooting Checklis Checklistt ............... ............................... ................................. ................................. ................................ ................................. ................................. ................................. ...................... ..... 9 Tools and Material Required for Servicing ............... ................................ ................................. ................................. .................................. ................................. ............................ ............ 10 Bolt Torque ............... ............................... ................................. ................................. ................................ ................................. ................................. ................................. ................................. .......................... .......... 11 Exploded Assembly View ............... ................................ ................................. ................................ ................................ ................................ ................................. ................................. ................ 12 12-1 -13 3 TC Service Parts List Chart ............. ............................. ............................... .............................. .............................. .............................. .................................. ................................... .................. 14 14-1 -15 5 TB Service Parts List Chart .............. ............................. ............................... ............................... ............................... ............................... ................................ ................................. .................. 16 16-1 -17 7 TE Service Parts List Chart .............. ............................. ............................... ............................... ............................... ............................... ................................ ................................. .................. 18 18-1 -19 9 TJ Service Parts List Chart ................ ............................... ............................... ................................ ................................ ............................... .................................. ................................... .................. .. 20 TF Service Parts List Chart ................ ............................... ............................... ............................... ............................... ............................... ................................. ................................ .............. 21-22 21-22 TG Service Parts List Chart ............... ............................... ............................... ............................... ................................ ................................ ................................. ............................... .............. 23-24 23-24 TH Service Parts List Chart ................ ............................... .............................. .............................. .............................. .............................. .................................. .................................. ............... 25-26 25-26 TL Service Parts List Chart ............... ............................... ................................ ................................ ................................ ................................. ................................. ................................. ................... .. 27 Disassembly & Inspection ................ ................................ ................................. ................................. ................................ ................................ ................................ .............................. .............. 28 28-3 -35 5 Torqmotor™ Assembly ..................................................................................................................................... 36-45 Rotor Set Component Assembly Procedure (One Piece Stator) .............. ............................... ................................. ................................. ............................. ............ 46 Rotor Set Component Assembly Procedure (Two (Two Piece Stator) ................. ................................. ................................ ................................. ....................... ...... 47 47-4 -48 8 Final Checks .............. ............................... ................................. ................................ ................................. ................................. ................................. ................................. ................................. ........................ ....... 49 Hydraulic Fluids ................ ................................ ................................ ................................. ................................. ................................ ................................ ................................. ................................. .................. .. 49 Filtration, Oil Temperature ........ .................. ................... ................... ................... ................... ................... ................... ................... ................... ................... ................... ................... ................... ............ 49 Tips for Maintaining the System ................ ............................... ............................... ................................ ................................ ................................ ................................ ............................. ............. 50 Offer of Sale ............... .............................. ............................... ................................ ................................ ............................... ............................... ................................ ................... ... Inside Back Cover

Definitions NOTE:

A NOTE provides key information to make a procedure easier or quicker to complete.

CAUTION:

A CAUTION refers refers to procedure that must be follow followed ed to avoid damaging the Torqmotor™ Torqmotor™ or other system components.

WARNING:

A WARNI WARNING NG REFERS TO PROCEDURE THA THAT T MUST BE FOLLOWED FOLLOWED FOR THE SAFETY SAFETY OF THE EQUIPMENT OPERA OPER ATOR AND THE PERSON INSPECTING OR REPAIRING THE TORQMOTOR™. TORQMOTOR™.

Disclaimer This Service Manual has been prepared by Parker Hannifin for reference and use by mechanics who have been trained to repair and service hydraulic motors and systems on commercial and non-commercial equipment applications. Parker Hannifin has exercised reasonable care and diligence to present accurate, clear and complete information and instructions regarding the techniques and tools required for maintaining, repairing and servicing the complete line of Parker TC, TB, TE, TJ, TF, TF, TG and TL Torqmotor TM Units. Howev However, er, despite the care and effort taken in preparing this general Service Manual, Parker makes no warranties that (a) the Service Manual or any explanations, illustrations, information, techniques or tools described herein are either accurate, complete or correct as applied to a specific Torqmotor™ unit, or (b) any repairs or service of a par ticular Torqmotor™ Torqmotor™ unit will result in a properly functioning Torqmotor™ Torqmotor™ unit. If inspection or testing reveals evidence of abnormal wear or damage to the Torqmotor™ unit or if you encounter circumstances not covered in the Manual, STOP – CONSULT THE EQUIPMENT MANUFACTURER’S SERVICE MANUAL AND WARRANTY.. DO NOT TRY TO WARRANTY TO REPAIR OR SERVICE A TORQMOTOR™ UNIT WHICH WH ICH HAS BEEN DAMAGED OR INCLUDES ANY PART THAT SHOWS EXCESSIVE WEAR UNLESS THE DAMAGED AND WORN PARTS ARE REPLACED WITH ORIGINAL PARKER REPLACEMENT AND SERVICE PARTS AND THE UNIT IS RESTORED TO PARKER SPECIFICATIONS FOR THE TORQMOTOR™ UNIT. It is the responsibility of the mechanic performing the maintenance, repairs or service on a particular Torqmotor™ unit to (a) inspect the unit for abnormal wear and damage, (b) choose a repair procedure which will not endanger his/her safety, the safety of others, the equipment, or the safe operation of the Torqmotor™, Torqmotor™, and (c) fully inspect and test the Torqmotor™ Torqmotor™ unit and the hydraulic system to insure that the repair or service of the Torqmotor™ unit has been properly performed and that the Torqmotor™ and hydraulic system will function properly.

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Torqmotor™ Service Ser vice Procedure TC,TB,, TE, TJ, TF, TC,TB TF, TG, TH and TL Serie Series s

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Torqmotor™ Design Features

Torqmotor™ TB/TC Series features Torqmotor™ fea tures include:

COUPLING SHAFT HIGH PRESSURE SEAL NEEDLE THRUST BEARING HOUSING DRIVE LINK— 12-TOOTH SPLINES

• The roller roller vane vane rotor rotor set set design design offers offers a low-friction, wear compensation which maximizes the useful performance life of the motor.

• Zero leak commutation valve provides greater, more consistent volumetric efficiency. • Desig Design n flexibili flexibility ty - TB TB offers offers the widest widest selection of shaft options, displacements and mounting flanges in the industry. • Pate Patented nted 60-40 60-40 spline spline memb member er arrangearrangement transmits more torque with less weight. • Full flow flow lubricat lubrication ion maximi maximizes zes cooling cooling and may provide up to 50% longer life than motors not having this feature.

DIRT & WATER WATER SEAL S EAL

• Highe Higherr pressure pressure rating rating provid provide e greater greater torque than competitive brands.

BUSHING

• Full interch interchangea angeabilit bility y with other other motors motors which are designed according to industry standards.

MATCHED ROTOR SET

• Compa Compatibl tible e with most hydrau hydraulic lic systems systems with regard to pressure, torque and speed.

MATCHED COMMUTA COM MUTATOR TOR SET

• A unique unique high-pre high-pressure ssure shaft shaft seal that that eliminates the need for case drains. • Up to 13 13 horsep horsepowe owerr output output..

COUPLING SHAFT

Torqmotor™ TE Series features featu res include:

HIGH PRESSURE SEAL NEEDLE THRUST BEARING HOUSING DRIVE LINK— 12-TOOTH SPLINES

• Rolle Rollerr vanes vanes to reduce frict friction ion and and internal leakage and to maintain efficiency.

• Zero leak commutation valve provides greater,, more consistent volumetric greater efficiency. • Wheel mount versio version n availa available. ble. • More start starting ing torque torque than than competi competitive tive motors in applications where the shaft is side loaded. (Competitive brands require more pressure to start the motor.) • A needle-ro needle-roller ller mounte mounted d coupling coupling shaft shaft and steel-caged thrust bearing which can withstand 1000-pound thrust loads. • Side load capacit capacity y is 1600 1600 lbs. (727. (727.3 3 kg) maximum at center of output shaft.

DIRT & WATER WATER SEAL S EAL

• A unique unique high-pre high-pressure ssure shaft shaft seal that that eliminates the need for case drains, check valves and extra plumbing.

NEEDLE RADIAL BEARING

• Up to 17 17 horsep horsepowe owerr output output.. • Great Greater er durabilit durability y due to superio superiorr lubricalubrication and minimum drive spline wear. • Pate Patented nted 60-40 60-40 spline spline memb member er arrangearrangement transmits more torque with less weight.

MATCHED ROTOR SET MATCHED COMMUTA COMM UTATOR TOR SET

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Torqmotor™ Service Procedure TC,TB, TE, TJ, TF, TG, TH and TL Series

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Torqmotor™ TF Series features include:

COUPLING SHAFT

• Heavy-duty thrust and roller bearings for up to twice side-load capacity to the previous motor.


HIGH PRESSURE SEAL NEEDLE THRUST BEARING

• Roller vanes to reduce friction and internal leakage, and to maintain efficiency. • A patented orbiting commutation system for less wear and longer life.

HOUSING DRIVE LINK— 12-TOOTH SPLINES

• A patented 60:40 arrangement of internal and external spline members to transmit more torque with less weight. • A unique high-pressure shaft seal that eliminates the need for case drains, check valves and extra plumbing. • A unique manifold designed to improve operating efficiency. • Up to 1000 lbs. (453.6 kg) end-thrust capacity in either direction. • A design that is less sensitive to contamination than competitive motors.

DIRT & WATER SEAL

• Up to 36 horsepower output. • Greater durability because of superior lubrication and minimum drive spline wear.


• Superior low speed performance.

• Zero leak commutation valve provides greater, more consistent volumetric efficiency.

MATCHED ROTOR SET MATCHED COMMUTATOR SET

HIGH PRESSURE SEAL COUPLING SHAFT

Torqmotor™ TG/ TH/TL Series features include:

NEEDLE THRUST BEARING • Roller vanes to reduce friction and internal HOUSING DRIVE LINK— 14-TOOTH SPLINES

leakage and to maintain efficiency. • A patented orbiting commutation system for less wear and longer life. • A patented 60:40 arrangement of internal and external spline members to transmit more torque with less weight. • A unique high-pressure shaft seal that eliminates the need for case drains, check valves and extra plumbing. • A manifold designed to improve operating efficiency. • Heavy-duty thrust and roller bearings for up to twice the side-load capacity to the previous motor.

DIRT & WATER SEAL

• Up to 1000 lbs. (453.6 kg) end-thrust capacity in either direction.


• A design that is less sensitive to contamination than competitive motors.

MATCHED ROTOR SET

• Up to 49 horsepower output.

MATCHED COMMUTATOR SET

• Greater durability because of superior lubrication and minimum drive spline wear.

• Zero leak commutation valve provides greater, more consistent volumetric efficiency.

5

Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 US

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Introduction This service manual has one purpose: to guide you in maintaining, troubleshooting, and servicing the TC, TB, TE, TJ, TF, TH and TL Torqmotor™ (low-speed, hightorque hydraulic motor).

A page with the Torqmotor™ exploded assembly view is provided several places in this manual. The component part names and item numbers assigned on this exploded assembly view correspond with names and item numbers (in parentheses) used in the disassembly and assembly procedures set forth in this manual.

Material in this manual is organized so you can work on the Torqmotor™ and get results without wasting time or being confused. To get these results, you should read this entire manual before you begin any work on the Torqmotor™.

Service part list charts are also provided in this manual with the part names and exploded view item numbers cross referenced to Parker service part numbers.

This manual also contains troubleshooting information and checklist. If you must service the Torqmotor™, the checklist will help you to determine where the problem may be.

Service parts are available through the Original Equipment Manufacturer or Parker approved TC, TB, TE, TJ, TF, TH and TL Distributors. As you gain experience in servicing the Torqmotor™, you may find that some information in this manual could be clearer or more complete. If so, let us know about it. Do not try to second guess the manual. If you are stuck, contact us. Servicing the Torqmotor™ should be a safe and productive procedure, in order for the unit to deliver the reliable, long-life operation engineered into it.

The three-column format of the Disassembly and Inspection, and Assembly sections will make it easier for you to conduct major work on the Torqmotor™. Column 1 gives a brief key for each procedure. Column 2 explains in detail the procedure you should follow. Column 3 illustrates this procedure with photographs. Read all material carefully and pay special attention to the notes, cautions, and warnings.

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Troubleshooting Guide


NOTE: Before troubleshooting any system problem, check service literature published by the equipment and/or component manufacturers. Follow their instructions, if given, for checking any component other than the Torqmotor™ unit.

Preparation

Hydraulic Components

Make your troubleshooting easier by preparing as follows:

If you think the problem is caused by a hydraulic component, start by checking the easy-to-reach items.

• work in a clean, well-lighted place;

Check all hoses and lines for cracks, hardening, or other signs of wear. Reroute any usable hoses that are kinked, severely bent, or that rest against hot engine parts. Look for leaks, especially at couplings and fittings. Replace any hoses or lines that don’t meet system flow and pressure ratings.

• have proper tools and materials nearby; • have an adequate supply of clean petroleum-based solvent. WARNING: SINCE SOLVENTS ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT, EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH.

Next, go to the reservoir and filter or filters. Check fluid level and look for air bubbles. Check the filter(s). A filter with a maximum 50 micron filtration i s recommended for the Torqmotor TM system.

WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA AND OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.

Visually check other components to see if they are loosely mounted, show signs of leaks, or other damage or wear. Excessive heat in a hydraulic system can create problems that can easily be overlooked. Every system has its limitation for the maximum amount of temperature. After the temperature is attained and passed, the following can occur:

Preliminary Checks Hydraulic systems are often trouble-free. Hence, the problem an operator complains of could be cause by something other than the hydraulic components. Thus, once you have determined that a problem exists, start with the easy-to-check items, such as:

• oil seal leaks

• parts damaged from impact that were not properly

• pump loss of efficiency

• loss of efficiency such as speed and torque

repaired, or that should have been replaced; and

• pump failure

• improper replacement parts used in previous servicing

• hoses become hard and brittle • hose failure

• mechanical linkage problems such as binding, broken, or loose parts or slipping belts

A normal temperature range means an efficient hydraulic system. Consult the manuals published by equipment and/or component manufacturers for maximum allowable temperature and hydraulic tests that may be necessary to run on the performance of the hydraulic components. The Torqmotor™ is not recommended for hydraulic systems with maximum temperatures above 200°F (93.3°C).

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Troubleshooting Checklist

Trouble

Cause

Remedy

Oil Leakage

1. Hose fittings loose, worn or damaged.

Check & replace damaged fittings or “O” Rings. Torque to manufacturers specifications.

2.Oil seal rings (4) deteriorated by excess heat.

Replace oil seal rings by disassembling Torqmotor™ unit.

3.Special bolt (1, 1A, 1B or 1C) loose or its sealing area deteriorated by corrosion.

(a) Loosen then tighten single bolt to torque specification. (b) Replace bolt.

Significant loss of speed under load

4.Internal shaft seal (16) worn or damaged.

Replace seal. Disassembly of Torqmotor™ unit necessary.

5.Worn coupling shaft (12) and internal seal (16).

Replace coupling shaft and seal by disassembling Torqmotor™ unit.

1. Lack of sufficient oil supply

(a) Check for faulty relief valve and adjust or replace as required. (b) Check for and repair worn pump. (c) Check for and use correct oil for temperature of operation.

Low mechanical efficiency or undue high pressure required to operate Torqmotor™ unit

2.High internal motor leakage

Replace worn rotor set by disassembling Torqmotor™ unit.

3.Severely worn or damaged internal splines.

Replace rotor set, drive link and coupling shaft by disassembling Torqmotor™ unit.

4.Excessive heat.

Locate excessive heat source (usually a restriction) in the system and correct the condition.

1. Line blockage

Locate blockage source and repair or replace.

2.Internal interference

Disassemble Torqmotor™ unit, identify and remedy cause and repair, replacing parts as necessary.

3.Lack of pumping pressure

Check for and repair worn pump.

4.Excessive binding or loading in system external to Torqmotor™ unit.

Locate source and eliminate cause.

CAUTION: If the hydraulic system fluid becomes overheated [in excess of 200°F (93.3°C)], seals in the system can shrink, harden or crack, thus losing their sealing ability. 9


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Tools and Materials Required for Servicing


• Clean, petroleum-based solvent • Emery paper • Vise with soft jaws • Air pressure source • Arbor press • Screw driver • Masking tape • Breaker bar • Torque wrench-ft. lbs. (N m) • Sockets: 1/2 or 9/16 inch thin wall, 1 inch • Allen Sockets: 3/16, 3/8 inch • Adjustable crescent wrench or hose fitting wrenches • SAE 10W40 SE or SF oil • Special bearing mandrel for TC, TB & TE Torqmotors (SEE FIGURE 1) • Special bearing mandrel for TH Torqmotors (consult factory) • Special bearing mandrel for TF, TG & TJ Torqmotors (SEE FIGURE 2) • Feeler gage .005 inch (.13 mm) • TC, TB & TE Torqmotors require blind hole bearing puller for 1.06 inch (26.9) mm) and 1.62 inch (41.1 mm) diameter bearing/bushing. • TH Torqmotors require blind hole bearing puller for a 1.575 inch dia. (40.0 mm) and 2.130 inch dia. (54.1 mm) bearings. • TJ, TF, TG & TL Torqmotors require blind hole bearing puller for 1.400 inch dia. (35.6 mm) and 2.130 inch dia. (54.1 mm) bearings. • Clean corrosion resistant grease. Part #406018 is included in each seal kit. Recommended grease is Parker Specification #045236 or Mobil Mobilith SHC® 460

NOTE: The available service seal kits include the recommended grease as a grease pack #406018 CAUTION: Mixing greases that have different bases can be detrimental to bearing life.

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Technical Information

CONVERSIONS INCHES .020 .021 .029 .030 .111 .119 .152 .160 .296 .304 .460 .470 .500 .585 .595 .660 .675 1.058

mm .51 .53 .74 .76 2.81 3.02 3.86 4.06 7.52 7.72 11.68 11.94 12.70 14.86 15.11 16.76 17.15 26.87

INCHES 1.060 1.295 1.297 1.396 1.398 1.620 1.622 1.983 1.985 2.120 2.122 2.233 2.235 2.483 2.485 2.500 2.88

mm 26.92 32.89 32.94 35.46 35.51 41.15 41.20 50.37 50.42 53.85 53.90 56.72 56.77 63.07 63.12 63.5 73.2

Torque Chart Part Name bolt 5/16 24 UNF 2A bolt 3/8 24 UNF 2A bolt 5/8 18 UNF 2A nut 3/4 16 UNF 2B nut 1-20 UNEF 2B

Item Number 1, 1A, 1B or 1C 1, 1A, 1B or 1C 12D 12B (TC, TB, TE) 12B (TF, TG, TL)

Torque 22-26 ft. lbs. (30-35 N m) 45-55 ft. lbs. (60-76 N m) 140-180 ft. lbs. (190-244 N m) 175-255 ft. lbs. (237-305 N m) 300-400 ft. lbs. (407-542 N m)

nut 1-1/8 18 UNEF 2B

12B (TG, TH)

300-400 ft. lbs. (407-542 N m)

- TC has two steel bushing internal of housing press first steel bushing 1.223 deep from housing face the second steel bushing press .03 below face - TL press internal bearing .576 below face.

(Fabricate if considered necessary)

(Fabricate if considered necessary)

Figure 1 – TC, TB & TE

Figure 2 – TF & TG (see note) 11


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Disassembly and Inspection


Preparation Before Disassembly • Before you disassemble the Torqmotor™ unit or any of its components read this entire manual. It provides important information on par ts and procedures you will need to know to service the Torqmotor™. • Determine whether the Torqmotor™ you are about to disassemble is the Small Frame Series TC, TB, TE or TJ or the Large Frame Series TF, TG, TL or TH so you can follow those procedures that per tain to that Series Torqmotor™. The first two letters of the “spec” number on the Torqmotor™ identification tag is the Series designation. Also determine the type of end construction from the alternate views shown on the exploded view. • The Small Frame Series TC, TB & TE Torqmotors™ will have a 3.66 inch (92.9 mm) main body outside diameter and five or six 5/16-24 UNF 2A cover bolts. The Medium Frame Series TJ Torqmotors™ will have a 3.66 inch (92.9 mm) main body outside diameter and six 5/16-24 UNF 2A cover bolts. The Large Frame Series TF, TG, TL & TH Torqmotors™ will have a 5 inch (127.9 mm) main body outside diameter and seven 3/8 24 UNF 2A cover bolts. • Refer to “Tools and Materials Required for Services” section for tools and other items required to service the Torqmotor™ and have them available. • Thoroughly clean off all outside dirt, especially from around fittings and hose connections, before disconnecting and removing the Torqmotor™. Remove rust or corrosion from coupling shaft. • Remove coupling shaft connections and hose fittings and immediately plug port holes and fluid lines. • Remove the Torqmotor™ from system, drain it of fluid and take it to a clean work surface. • Clean and dry the Torqmotor™ before you start to disassemble the unit. • As you disassemble the Torqmotor™ clean all parts, except seals, in clean petroleum-based solvent, and blow them dry. WARNING: petroleum-base solvents are flammable. Be extremely careful when using any solvent. Even a small explosion or fire could cause injury or death. WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. CAUTION: Never steam or high pressure wash hydraulic components. Do not force or abuse closely fitted par ts. • Keep parts separate to avoid nicks and burrs. • Discard all seals and seal rings as they are removed from the Torqmotor™. Replace all seals, seal rings and any damaged or worn parts with genuine Parker or OEM approved service parts.

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Reference Exploded Assembly View Place Torqmotor in a vise

WARNING

Scribe alignment mark & loose valve plugs

1.

Place the Torqmotor™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port O-Rings (18A) if applicable.

WARNING: IF THE TORQMOTOR™ IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED DURING THE SERVICE PROCEDURES, CAUSING INJURY.

2. Scribe an alignment mark down and across the Torqmotor™ components from end cover (2) to housing (18) to facilitate reassembly orientation where required. Loosen two shuttle or relief valve plugs (21) for disassembly later if included in end cover. 3/16 or 3/8 inch Allen wrench or 1 inch hex socket required. SEE FIGURES 3 & 4.

Figure 3

Figure 4

Figure 5

Remove special bolts & inspect bolts

3. Remove the five, six, or seven special ring head bolts (1, 1A, 1B, or 1C) using an appropriate 1/2 or 9/16 inch size socket. SEE FIGURE 5. Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts. SEE FIGURE 6.

Figure 6

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Disassembly and Inspection Remove end cover & inspect bolts


4. Remove end cover assembly (2) and seal ring (4). Discard seal ring. SEE FIGURE 7.

NOTE

NOTE: Refer to the appropriate “alternate cover construction” on the exploded view to determine the end cover construction being serviced. Figure 7

Remove plugs and valves

5. If the end cover (2) is equipped with shuttle valve or relief valve (24) components, remove the two previously loosened plugs (21) and o-rings (22). SEE FIGURE 8.

CAUTION

CAUTION: Be ready to catch the shuttle valve or relief valve components that will fall out of the end cover valve cavity when the plugs are removed.

NOTE

NOTE: O-ring (22) is not included in seal kits but serviced separately if required.

NOTE

NOTE: The insert and if included the orifice plug in the end cover (2) must not be removed as they are serviced as an integral part of the end cover.

Wash & inspect end cover

Figure 8

6. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. SEE FIGURE 9. Figure 9

NOTE

Remove & inspect commutator ring

NOTE: A polished pattern (not scratches) on the cover from rotation of the commutator (5) is normal. Discoloration would indicate excess fluid temperature, thermal shock, or excess speed and require system investigation for cause and close inspection of end cover, commutator, manifold, and rotor set. 7.

Remove commutator ring (6). SEE FIGURE 10. Inspect commutator ring for cracks, or burrs.

Figure 10

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Disassembly and Inspection Remove & inspect commutator

8.

Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinelling. If any of these conditions exist, replace commutator and commutator ring as a matched set. SEE FIGURE 11 & 12.

Remove manifold

9.

Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling. Replace manifold if any of these conditions exist. SEE FIGURE 13. A polished pattern on the ground surface from commutator or rotor rotation is normal. Remove and discard the seal rings (4) that are on both sides of the manifold.

NOTE

Remove & inspect rotor set & wearplate

NOTE

Figure 11

NOTE:The manifold is constructed of plates bonded together to form an integral component not subject to further disassembly for service. Compare configuration of both sides of the manifold to ensure that same surface is reassembled against the rotor set. 10. Remove rotor set (8) and wearplate (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C) to stator (8B) contact surfaces. SEE FIGURE 14. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wearplate. You may have to shift the rotor set on the wearplate to work the drive link out of the rotor (8A) and wearplate. SEE FIGURE 15. Inspect the rotor set in its assembled form for nicks, scoring, or spalling on any surface and for broken or worn splines. If the rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect the wearplate for cracks, brinelling, or scoring. Discard seal ring (4) that is between the rotor set and wearplate.

NOTE: The rotor set (8) components may become disassembled during service procedures. Marking the surface of the rotor and stator that is facing UP, with etching ink or grease pencil before removal from Torqmotor™ will ensure correct reassembly of rotor into stator and rotor set into Torqmotor™. Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maximum wear life and performance of rotor set and Torqmotor™. 31

Figure 12

Figure 13

Figure 14 Parker Hannifin Corporation Hydraulic Pump/Motor Division Greeneville, TN 37745 US

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NOTE

NOTE: Series TG or TH may have a rotor set with two stator halves (8B & 8D) with a seal ring (4) between them and two sets of seven vanes (8C & 8E). Discard seal ring only if stator halves become disassembled during the service procedures.

NOTE

NOTE: A polished pattern on the wear plate from rotor rotation is normal.

Check rotor, vance clearance

Figure 15

11. Place rotor set (8) and wear plate (9) on a flat surface and center rotor (8A) in stator (8B) such that two rotor lobes (180 degrees apar t) and a roller vane (8C) centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gage at this common centerline. If there is more than .005 inches (0.13 mm) of clearance, replace rotor set. SEE FIGURE 16. Figure 16

NOTE

Remove & inspect drive link

Remove thrust bearing

NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets of seven vanes (8C & 8E) as shown in the alternate construction TG rotor set assembly view, check the rotor lobe to roller vane clearance at both ends of rotor.

12. Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. SEE FIGURE 17. Remove and discard seal ring (4) from housing (18).

Figure 17

13. Remove thrust bearing (11) from top of coupling shaft (12) if Torqmotor is a Series TF, TG, TH or TL. Inspect for wear, brinelling, corrosion and a full complement of retained rollers. SEE FIGURE 18.

Figure 18

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Disassembly and Inspection Check coupling shaft for rust or corrosion

14. Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used. SEE FIGURE 19. Remove any key (12A), nut (12B), washer (12C), bolt (12D), lock washer (12E), or retaining ring (12F).

Figure 19

Remove & inspect coupling shaft

15. Remove coupling shaft (12), by pushing on the output end of shaft. SEE FIGURE 20. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external splines or keyway. SEE FIGURE 21. Replace coupling shaft if any of these conditions exist.

NOTE

NOTE: Minor shaft wear in seal area is permissible. If wear exceeds .020 inches (0.51 mm) diametrically, replace coupling shaft.

NOTE

NOTE: A slight “polish” is permissible in the shaft bearing areas. Anything more would require coupling shaft replacement.

Remove seal ring from housing

16. Remove and discard seal ring (4) from housing (18).

Remove & inspect thrust washer & thrust bearing

17. Remove thrust bearing (15) and thrust washer (14) if the unit is a Series TC, TB or TE. Inspect for wear, brinelling, corrosion and a full complement of retained rollers. SEE FIGURE 22. Note: The TL motor has only one thrust bearing and washer.

Figure 20

Figure 21

NOTE NOTE: Large Frame Series TF,TG & TJ Torqmotors have a thrust bearing (15) sandwiched between two thrust washers (14) that cannot be removed from housing (18) unless bearing (13) is removed for replacement. 33


HY13-1512-004-M1/USA

Disassembly and Inspection Remove seal & washer or washers


18. Remove seal (16) and back up ring (17) from Small Frame, TC, TB & TE housing (18) and backup washer (25). Discard both. SEE FIGURE 23. Remove seal (16), backup ring (17), and backup washer (25) from Large Frame, Series TF, TG, TJ and TH housing by working them around unseated thrust washers (14) and thrust bearing (15) and out of the housing. Discard seal and washers. SEE FIGURE 24.

NOTE

Figure 23

NOTE: The original design units of Large & Small Frame Torqmotors™ did not include backup washer (25), but must include backup washer (25) when reassembled for service.

Figure 24

Remove seal

19. Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hol e bearing or seal puller is required. SEE FIGURE 25.

Figure 25

Inspect housing assembly

20. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. SEE FIGURE 26. If the housing is defective in these areas, discard the housing assembly.

Figure 26

34



HY13-1512-004-M1/USA

Disassembly and Inspection Inspect housing bearing/bushing

NOTE

21. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. SEE FIGURE 27. The TB Series bushing (19) or (13) to coupling shaft diameter clearance must not exceed .010 inch (.025 mm). A bearing, bushing, or thrust washer that does not pass inspection must be replaced. SEE FIGURE 28. If the housing has passed this inspection the disassembly of the Torqmotor™ is completed.

NOTE: The depth or location of bearing/ bushing (13) in relation to the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counter bore should be measured and noted before removing the bearings/ bushings. This will facilitate the correct reassembly of new bearings/bushings. SEE FIGURE 29.

Figure 27

Figure 28

Figure 29

Remove bearings or bushings & thrust washers

22. If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13). SEE FIGURES 30 & 31.

Figure 30

THE DISASSEMBLY OF TORQMOTOR™ IS COMPLETED. 35


HY13-1512-004-M1/USA

Torqmotor™ Assembly


•

Replace all seals and seal rings with new ones each time you reassemble the Torqmotor™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly.

•

NOTE: Individual seals and seal rings as well as a complete seal kit are available. SEE FIGURE 32. The parts should be available through most OEM parts distributors or Parker approved Torqmotor™ distributors. (Contact your local dealer for availability).

•

NOTE: Unless otherwise indicated, do not oil or grease parts before assembly.

•

Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear plate and housing and from port and sealing areas.

WARNING

WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH.

WARNING

WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.

Press in outer bearing/bushing

1.

If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing (19) with clean corrosion resistant grease recommended in the material section. Press the new bearing/ bushing into the counterbore at the mounting flange end of the housing, using the appropriate sized bearing mandrel such as described in figure 1 or figure 2 which will control the bearing/ bushing depth. Small Frame Series TB and TE Torqmotor™ housings require the use of bearing mandrel shown in figure 1 to press bearing/ bushing (19) into the housing to a required depth of .151/.161 inches (3.84/4.09 mm) from the end of the bearing counterbore. SEE FIGURE 33. (TC reference page 10).

Figure 32, TF, TG seal kit

Figure 33

Large Frame Series TF, TG & TJ Torqmotor™ housings require the use of the bearing mandrel shown in figure 2 to press bearing (19) into the housing to a required depth of .290/ .310 inches (7.37/7,87 mm) from the outside end of the bearing counterbore. SEE FIGURE 34. Large Frame Series TH Torqmotor housings require the use of a bearing mandrel. Consult factory for specifications. 36



HY13-1512-004-M1/USA

Torqmotor™ Assembly NOTE

NOTE: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square with the press base and the bearing/ bushing is not cocked when pressing a bearing/bushing into the housing.

CAUTION

CAUTION: If the bearing mandrel specified in the “Tools and Materials Required for Servicing” section is not available and alternate methods are used to press in bearing/bushing (13) and (19) the bearing/ bushing depths specified must be achieved to insure adequate bearing support and correct relationship to adjacent components when assembled. SEE FIGURE 35.

CAUTION

Figure 35

CAUTION: Because the bearing/bushings (13) and (19) have a press fit into the housing they must be discarded when removed. They must not be reused.

Figure 36

Press in inner bearing/bushing

2.

The Small Frame Series TB and TE Torqmotor™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to .03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/bushing (19). Reference figure 1, “Tools and Materials Required for Servicing” section. SEE FIGURE 36. The Large Frame Series TF, TG & TJ Torqmotor™ housing (18) requires that you assemble a new backup washer (25) & backup ring (17), new seal (16), with the lip facing to the inside of Torqmotor (see figure 69A), new thrust washer (14), new thrust bearing (15) and a new second thrust washer (14) in that order before pressing in the inner housing bearing (13). SEE FIGURE 37 & 38. When these components are in place, press new bearing (13) into the housing (18) to a depth of .105/.125 inches (2.67/3.18), .03 inches max for TJ (.76) below the housing wear plate contact face. Use the opposite end of the bearing mandrel used to press in outer bearing (19). Reference figure 2, in the “Tools and Materials Required for Servicing” section. SEE FIGURE 39. 37

Figure 37


HY13-1512-004-M1/USA

Torqmotor™ Assembly Press in dirt & water seal

3.


Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore.

Figure 39

The Small Frame Series TC, TB and TE Torqmotor™ dirt and water seal (20) must be pressed in until its’ flange is flush against the housing. SEE FIGURE 40.

Figure 40

The Large Frame Series TF, TG, TJ & TH Torqmotor™ dirt and water seal (20) must be pressed in with the lip facing out and until the seal is flush to .020 inches (.51 mm) below the end of housing. SEE FIGURE 41.

Figure 41

Place housing assembly into vice

4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. SEE FIGURE 42.

Figure 42

38



HY13-1512-004-M1/USA


Assemble backup 5. On Small Frame, Series TC, TB & TE washer & seal Torqmotors™ assemble a new backup ring (17), new bakcup washer (25) and new seal (16) with the seal lip facing toward the inside of Torqmotor™ (see Figure 69B), into their respective counterbores in housing (18) if they were not assembled in procedure 2. Large Frame, Series TF, TG, TJ & TH Torqmotor™ housing (18) that did not require replacement of the bearing package will require that the two “captured” thrust washers (14) and thrust bearing (15) be unseated and vertical to the counterbore and the new backup ring (17), new backup washer (25), and new seal (16) be worked around the thrust bearing package and placed into their respective counterbores. The seal lip must face out of the seal counterbore and toward the inside of Torqmotor™ (see figure 69A). Be sure the thrust bearing package is reseated correctly after assembly of the seal and backup washer. SEE FIGURES 43 & 44.

CAUTION

CAUTION: Original design Large Frame, TF & TG Torqmotors™ that do not have backup washer (25) when disassembled must be assembled with a new backup ring (17), new backup washer (25), and new seal (16).

Figure 43

Figure 44

Assemble thrust 6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Series washer & bearing TB or TE Torqmotor™. SEE FIGURE 45. NOTE

Apply masking tape to shaft

NOTE: Small Frame Series TC, TB and TE Torqmotors™ require one thrust washer (14) with thrust bearing (15).The coupling shaft will be seated directly against the thrust bearing.

Figure 45

7. Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal. SEE FIGURE 46.

Figure 46

39


HY13-1512-004-M1/USA



Install coupling shaft

8. Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in TC, TB and TE Series housings and against the second thrust washer (14) in TF and TG Series housings. SEE FIGURE 47.

CAUTION

CAUTION:The outer bearing (19) is not lubricated by the system’s hydraulic fluid. Be sure it is thoroughly packed with the recommended grease, Parker Gear grease specification #045236, E/M Lubricant #K-70M.

NOTE

NOTE: Mobil Mobilith SHC ® 460 NOTE: A 102 Tube (P/N 406010) is included in each seal kit.

NOTE

NOTE: The coupling shaft (12) will be flush or just below the housing wear surface on Small Frame, Series TC, TB, TE & TJ Torqmotors™ when properly seated while the coupling shaft (12) on Large Frame, Series TF, TG, or TH Torqmotors™ will be approximately .10 inch (2.54 mm) below the housing wear plate surface to allow the assembly of thrust bearing (11). The coupling shaft must rotate smoothly on the thrust bearing package. SEE FIGURE 48.

Install thrust bearing

9. Install thrust bearing (11) onto the end of coupling shaft (12) only if you are servicing an TF, TG, TH or TL Series Torqmotor™. SEE FIGURE 49.

Insert seal ring

10. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. SEE FIGURE 50.

NOTE

NOTE: One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off the heads of either 3/8-24 UNF 2A or 5/16-24 UNF 2A bolts as required that are over .5 inch (12.7 mm) longer than the bolts (1, 1A, 1B, or 1C) used in the Torqmotor™. 40

Figure 47

Figure 48

Figure 49



HY13-1512-004-M1/USA

Torqmotor™ Assembly Install drive link

NOTE

11. Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines. SEE FIGURE 51.

NOTE: Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in their original position in the mating coupling shaft splines. Figure 51

Assemble wear plate

12. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). SEE FIGURE 52.

Assemble seal ring

13. Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator (8B). SEE FIGURE 53.

Install the assembled rotor set

14. Install the assembled rotor set (8) onto wear plate (9) with rotor (8A) counterbore and seal ring side down and the splines into mesh with the drive link splines. SEE FIGURE 54.

NOTE

NOTE: It may be necessary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link.

NOTE

NOTE: If necessary, go to the appropriate, “Rotor Set Component Assembly Procedure.”

NOTE

NOTE: The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor-drive link spline contact. A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent, to determine which side was down. The rotor set seal ring groove faces toward the wear plate (9). 41

Figure 52

Figure 53


HY13-1512-004-M1/USA

Torqmotor™ Assembly Assemble seal ring in manifold

NOTE

Assemble manifold


15. Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7). SEE FIGURE 55.

NOTE: The manifold (7) is made up of several plates bonded together permanently to form an integral component. The manifold surface that must contact the rotor set has it’s series of irregular shaped cavities on the largest circumference or circle around the inside diameter. The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set.

Figure 55

16. Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set. SEE FIGURE 56.

Figure 56

Insert a seal in manifold

17. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. SEE FIGURE 57.

Figure 57

Assemble commutator ring

18. Assemble the commutator ring (6) over alignment studs onto the manifold. SEE FIGURE 58.

Figure 58

42



HY13-1512-004-M1/USA

Torqmotor™ Assembly Assemble seal & commutator

19. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up. SEE FIGURE 59, 60.

Figure 59

Figure 60

Assemble shuttle 20. If shuttle valve components items #21, #22, valve parts into #23, #24 were removed from the end cover end cover (2) turn a plug (21) with a new o-ring (22), loosely into one end of the valve cavity in the end cover. Insert a spring (23) the valve (24) and the second spring (23) into the other end of the valve cavity. Turn the second plug (21) with a new o-ring (22) loosely into the end cover valve cavity. 3/16 inch Allen wrench required. SEE FIGURE 61. Figure 61

Assemble relief valve parts in end cover

21. If relief valve components items #21, #22, #24 were removed from the end cover (2) assemble a new o-ring (22) on the two plugs (21). Assemble a two piece relief valve (24) in each of the plugs, with the large end of the conical spring into the plug first and the small nut of the other valve piece in the small end of the conical spring. Turn each of the plug and relief valve assemblies into the end cover loosely to be torqued later. 3/8 inch Allen or 1 inch Hex socket required. SEE FIGURE 62. 43


HY13-1512-004-M1/USA

Torqmotor™ Assembly Assemble seal ring & end cover


22. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. SEE FIGURE 63, 64. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18). The correct 5 bolt end cover bolt hole relationship to housing port bosses is shown in FIGURE 65. Figure 63

NOTE

NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position.

Figure 64

Figure 65

Assemble cover bolts

23. Assemble the 5, 6 or 7 special bolts (1, 1A, 1B or 1C) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in pl ace. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 22-26 ft. lbs. (30-35 N m) for the five TC, TB or six TE Series 5/16 24 threaded bolts or six TJ bolts or 45-55 ft. lbs. (61-75 N m) for th e seven TF, TG & TL Series 3/8-24 threaded bolts. SEE FIGURE 66, 67, 68. 44



HY13-1512-004-M1/USA

Torqmotor™ Assembly NOTE

NOTE: The special bolts required for use with the relief or shuttle valve (24) end cover assembly (2) are longer than the bolts required with standard and cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required.

Figure 67

Figure 68

Torque the valve plugs

24. Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9-12 ft. lbs. (12-16 N m) if cover is so equi pped. SEE FIGURE 69. Torque the two relief valve plug assemblies (21) in end cover assembly to 45-55 ft. lbs. (61-75 N m) if cover is so equipped.

Figure 69 Thrust Washers

Thrust Washers

Housing

Housing

Backup Washer Backup Washer Seal

Seal

Thrust Bearing Not To Scale

Backup Ring

Shaft Not To Scale

Figure 69A

Large Frame

Backup Ring

Thrust Bearing

Figure 69B

Shaft Small Frame

THE ASSEMBLY OF THE TORQMOTOR™ IS NOW COMPLETE EXCEPT FOR WOODRUFF KEY (12A), NUT (12B), WASHER (12C), BOLT (12D), LOCKWASHER (12E), RETAINER RING (12F) or PORT O-RINGS (18A) AT INSTALLATION IF APPLICABLE. PROCEED TO FINAL CHECKS SECTION. 45


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Rotor Set Component Assembly


One Piece Stator Construction A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembled by the following procedures.

Assemble stator

1. Place stator (8B) onto wear plate (9) with seal ring (4) side down, after following Torqmotor™ assembly procedures 1 through 13. Be sure the seal ring is in place. SEE FIGURE 70.

Insert two bolts

2. If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing bolt holes and turn two bolts (1) finger tight into bolt holes approximately 180 degrees apart to retain stator and wear plate stationary.

Assemble rotor

NOTE

Assemble vanes

CAUTION

Figure 70

3. Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines. SEE FIGURE 71.

NOTE: If the manifold side of the rotor was etched during Torqmotor disassembly, this side should be up. If the rotor is not etched and does not have a counterbore, use the drive link spline contact pattern apparent on the rotor splines to determine the rotor side that must be against the wear plate.

Figure 71

4. Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets. SEE FIGURE 72.

CAUTION: Excessive force used to push the rotor vanes into place could shear off the coating applied to the stator vane pockets.

Assemble full complement of vanes

5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator (8B), creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force. SEE FIGURE 73.

Remove two assembled bolts

6. Remove the two assembled bolts (1) if used to retain stator and wear plate. Go to Torqmotor™ assembly procedure #15, to continue Torqmotor™ assembly. 46

Figure 72



HY13-1512-004-M1/USA

Rotor Set Component Assembly

Two Piece Stator Construction A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be assembled by the following procedures.

Assemble stator halves

1. Place stator half (8B) onto wear plate (9) with seal ring (4) side down, after following Torqmotor™ assembly procedures 1 through 13. Be sure the seal ring is in place.

Insert two alignment studs

2. Align stator bolt holes with wear plate and housing bolts and turn two alignment studs finger tight into bolt holes approximately 180 degrees apart to retain stator half and wear plate stationary.

Assemble rotor

3.

NOTE

Assemble vanes

CAUTION

Assemble rotor (8A), counterbore down if applicable, into stator half (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines.

NOTE: Use any marking you applied to rotor set components to reassemble the components in their original relationship to ensure ultimate wear life and performance.

4.

Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets.

CAUTION: Excessive force used to push the rotor vanes into place could shear off the coating applied to the stator vane pockets.


5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator half (8B), creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

Assemble seal ring in stator half

6. Place second stator half (8D) on a flat surface with seal ring groove up. Apply a small amount of grease to a new seal ring (4) and assemble it into stator half ring groove. 47


HY13-1512-004-M1/USA

Rotor Set Component Assembly Assemble second stator half


7. Assemble the second stator half (8D) over the two alignment studs and rotor (8A) with seal ring side down onto the first stator half (8B) aligning any timing marks applied for this purpose.

CAUTION

CAUTION: If the stator half (8B) is a different height (thickness) than stator half (8D) the stator vanes (8C) or (8E) of the same length (height) as the stator half must be reassembled in their respective stator half for the rotor set to function properly.

Assemble vanes

8.


9. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8E) into stator (8D), creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

Assemble six vanes (8E), or as many vanes that will readily assemble into the stator vane pockets.

Go to Torqmotor™ assembly procedure #15, to continue Torqmotor™ assembly.

48



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Final Checks

Final Checks •

Pressurize the Torqmotor™ with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for external leaks.

•

Check Torqmotor™ for rotation. Torque required to rotate coupling shaft should not be more than 50 ft. lbs. (68 N m)

•

On TB, TE & TJ Series Torqmotors, pressure port with “A” cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with “B” cast under it is for counter clockwise coupling shaft rotation.

•

On TF, TG, & TH Series Torqmotors, pressure port with “B” cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with “A” case under it is for counter clockwise coupling shaft rotation.

•

Use test stand if available, to check operation of the Torqmotor™.

Hydraulic Fluid Keep the hydraulic system filled with one of the following: •

10W40 SE or SF manufacturers suggested oil.

•

Hydraulic fluid as recommended by equipment manufacturer, but the viscosity should not drop below 50 SSU or contain less than .125% zinc anti-wear additives.

CAUTION: Do not mix oil types. Any mixture, or an unapproved oil, could deteriorate the seals. Maintain the proper fluid level in the reservoir. When changing fluid, completely drain old oil from the system. It is suggested also that you flush the system with clean oil.

Filtration Recommended filtration 20-50 micron.

Oil Temperature Maximum operating temperature 200°F (93.3° C).

49


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Tips


Tips for Maintaining the Torqmotor™ Hydraulic System •

Adjust fluid level in reservoir as necessary.

•

Encourage all operators to report any malfunction or accident that may have damaged the hydraulic system or component.

•

Do not attempt to weld any broken Torqmotor™ component. Replace the component with original equipment only.

•

Do not cold straighten, hot straighten, or bend any Torqmotor™ part.

•

Prevent dirt or other foreign matter from entering the hydraulic system. Clean the area around and the filler caps before checking oil level.

•

Investigate and correct any external leak in the hydraulic system, no matter how minor the leak.

•

Comply with manufacturer’s specifications for cleaning or replacing the filter.

CAUTION: Do not weld, braze, solder or any way alter any Torqmotor™ component. CAUTION: Maximum operating pressure must not exceed recommended Torqmotor™ pressure capacity. CAUTION: Always carefully inspect any system component that may have been struck or damaged during operation or in an accident. Replace any component that is damaged or that is questionable. CAUTION: Do not force any coupling onto the Torqmotor™ coupling shaft as this could damage the unit internally. Parker extends close technical cooperation and assistance. If problems occur which you cannot solve, please contact your local Parker approved Distributor or Parker Technical Support. Our phone number and fax number and address are on the back cover of this manual.

50



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Notes

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Notes


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Notes

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Notes


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Offer of Sale

The items described in this document and other documents or descriptions provided by Parker Hannifin Corporation, its subsidiaries and its authorized distributors are hereby offered for sale at prices to be established by Parker Hannifin Corporation, its subsidiaries and its authorized distributors. This offer and its acceptance by any customer ("Buyer") shall be governed by all of the following Terms and Conditions. Buyer’s order for any such items, when communicated to Parker Hannifin Corporation, its subsidiary or an authorized distributor ("Seller") verbally or in writing, shall constitute acceptance of this offer.

1. Terms and Conditions of Sale: All descriptions, quotations, proposals, offers, acknowledgments, acceptances and sales of Seller’s products are subject to and shall be governed exclusively by the terms and conditions stated herein. Buyer’s acceptance of any offer to sell is limited to these terms and conditions. Any terms or conditions in addition to, or inconsistent with those stated herein, proposed by Buyer in any acceptance of an offer by Seller, are hereby objected to. No such additional, different or inconsistent terms and conditions shall become part of the contract between Buyer and Seller unless expressly accepted in writing by Seller. Seller’s acceptance of any offer to purchase by Buyer is expressly conditional upon Buyer’s assent to all the terms and conditions stated herein, including any terms in addition to, or inconsistent with those contained in Buyer’s offer, Acceptance of Seller’s products shall in all events constitute such assent. 2. Payment: Payment shall be made by Buyer net 30 days from the date of delivery of the items purchased hereunder. Amounts not timely paid shall bear interest at the maximum rate permitted by law for each month or portion thereof that the Buyer is late in making payment. Any claims by Buyer for omissions or shortages in a shipment shall be waived unless Seller receives notice thereof within 30 days after Buyer’s receipt of the shipment. 3. Delivery: Unless otherwise provided on the face hereof, delivery shall be made F.O.B. Seller’s plant. Regardless of the method of delivery, however, risk of loss shall pass to Buyer upon Seller’s delivery to a carrier. Any delivery dates shown are approximate only and Seller shall have no liability for any delays in delivery. 4. Warranty: Seller warrants that the items sold hereunder shall be free from defects in material or workmanship for a period of 18 months from date of shipment from Parker Hannifin Corporation. THIS WARRANTY COMPRISES THE SOLE AND ENTIRE WARRANTY PERTAINING TO ITEMS PROVIDED HEREUNDER. SELLER MAKES NO OTHER WARRANTY, GUARANTEE, OR REPRESENTATION OF ANY KIND WHATSOEVER. ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO, MERCHANTABILITY AND FITNESS FOR PURPOSE, WHETHER EXPRESS, IMPLIED, OR ARISING BY OPERATION OF LAW, TRADE USAGE, OR COURSE OF DEALING ARE HEREBY DISCLAIMED. NOTWITHSTANDING THE FOREGOING, THERE ARE NO WARRANTIES WHATSOEVER ON ITEMS BUILT OR ACQUIRED WHOLLY OR PARTIALLY, TO BUYER’S DESIGNS OR SPECIFICATIONS. 5. Limitation Of Remedy: SELLER’S LIABILITY ARISING FROM OR IN ANY WAY CONNECTED WITH THE ITEMS SOLD OR THIS CONTRACT SHALL BE LIMITED EXCLUSIVELY TO REPAIR O R REPLACEMENT OF THE ITEMS SOLD OR REFUND OF THE PURCHASE PRICE PAID BY BUYER, AT SELLER’S SOLE OPTION. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND OR NATURE WHATSOEVER, INCLUDING BUT NOT LIMITED TO LOST PROFITS ARISING FROM OR IN ANY WAY CONNECTED WITH THIS AGREEMENT OR ITEMS SOLD HEREUNDER, WHETHER ALLEGED TO ARISE FROM BREACH OF CONTRACT, EXPRESS OR IMPLIED WARRANTY, OR IN TORT, INCLUDING WITHOUT LIMITATION, NEGLIGENCE, FAILURE TO WARN OR STRICT LIABILITY. 6. Changes, Reschedules and Cancellations: Buyer may request to modify the designs or specifications for the items sold hereunder as well as the quantities and delivery dates thereof, or may request to cancel all or part of this order, however, no such requested modification or cancellation shall become part of the contract between Buyer and Seller unless accepted by Seller in a written amendment to this Agreement. Acceptance of any such requested modification or cancellation shall be at Seller’s discretion, and shall be upon such terms and conditions as Seller may require. 7. Special Tooling: A tooling charge may be imposed for any special tooling, including without limitation, dies, fixtures, molds and patterns, acquired to manufacture items sold pursuant to this contract. Such special tooling shall be and remain Seller’s property notwithstanding payment of any charges by Buyer. In no event will Buyer acquire any interest in apparatus belonging to Seller which is utilized in the manufacture of the items sold hereunder, even if such apparatus has been specially converted or adapted for such manufacture and notwithstanding any charges paid by Buyer. Unless otherwise agreed, Seller shall have the

right to alter, discard or otherwise dispose of any special tooling or other property in its sole discretion at any time. 8. Buyer’s Property: Any designs, tools, patterns, materials, drawings, confidential information or equipment furnished by Buyer or any other items which become Buyer’s property, may be considered obsolete and may be destroyed by Seller after two (2) consecutive years have elapsed without Buyer placing an order for the items which are manufactured using such property, Seller shall not be responsible for any loss or damage to such property while it is in Seller’s possession or control. 9. Taxes: Unless otherwise indicated on the face hereof, all prices and charges are exclusive of excise, sales, use, property, occupational or like taxes which may be imposed by any taxing authority upon the manufacture, sale or delivery of the items sold hereunder. If any such taxes must be paid by Seller or if Seller is liabl e for the collection of such tax, the amou nt thereof shall be in addition to the amounts for the items sold. Buyer agrees to pay all such taxes or to reimburse Seller therefore upon receipt of its invoice. If Buyer claims exemption from any sales, use or other tax imposed by any taxing authority, Buyer shall save Seller harmless from and against any such tax, together with any interest or penalties thereon which may be assessed if the items are held to be taxable. 10. Indemnity For Infringement of Intellectual Property Rights: Seller shall have no liability for infringement of any patents, trademarks, copyrights, trade dress, trade secrets or similar rights except as provided in this Part 10. Seller will defend and indemnify Buyer against allegations of infringement of U.S. Patents, U.S. Trademarks, copyrights, trade dress and trade secrets (hereinafter ‘Intellectual Property Rights’). Seller will defend at its expense and will pay the cost of any settlement or damages awarded in an action brought against Buyer based on an allegation that an item sold pursuant to this contract infringes the Intellectual Property Rights of a third party. Seller’s obligation to defend and indemnify Buyer is contingent on Buyer notifying Seller within ten (10) days after Buyer becomes aware of such allegations of infringement, and Seller having sole control over the defense of any allegations or actions including all negotiations for settlement or compromise. If an item sold hereunder is subject to a claim that it infringes the Intellectual Property Rights of a third party, Seller may, at its sole expense and option, procure for Buyer the right to continue using said item, replace or modify said item so as to make it noninfringing, or offer to accept return of said item and return the purchase price less a reasonable allowance for depreciation. Notwithstanding the foregoing, Seller shall have no liability for claims of infringement based on information provided by Buyer, or directed to items delivered hereunder for which the designs are specified in whole or part by Buyer, or infringements resulting from the modification, combination or use in a system of any item sold hereunder. The foregoing provisions of this Part 10 shall constitute Seller’s sole and exclusive liability and Buyer’s sole and exclusive remedy for infringement of Intellectual Property Rights. If a claim is based on information provided by Buyer or if the design for an item delivered hereunder is specified in whole or in part by Buyer, Buyer shall defend and indemnify Seller for all costs, expenses or judgments resulting from any claim that such item infringes any patent, trademark, copyright, trade dress, trade secret or any similar right. 11. Force Majeure: Seller does not assume the risk of and shall not be liable for delay or failure to perform any of Seller’s obligations by reason of circumstances beyond the reasonable control of Seller (hereinafter ‘Events of Force Majeure’). Events of Force Majeure shall include without limitation, accidents, acts of God, strikes or labor disputes, acts, laws, rules or regulations of any government or government agency, fires, floods, delays or failures in delivery of carriers or suppliers, shortages of materials and any other cause beyond Seller’s control. 12. Entire Agreement/Governing Law: The terms and conditions set forth herein, together with any amendments, modifications and any different terms or conditions expressly accepted by Seller in writing, shall constitute the entire Agreement concerning the items sold, and there are no oral or other representations or agreements which pertain thereto. This Agreement shall be governed in all respects by the law of the State of Ohio. No actions arising out of the sale of the items sold hereunder or this Agreement may be brought by either party more than two (2) years after the cause of action accrues. 9/91-P

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Parker Hannifin Corporation 2745 Snapps Ferry Road Greeneville, TN 37745 USA Tel: (423) 639-8151 FA X: (423) 787-2418 www.parker.com/pumpmotor

Installation and Maintenance Instructions Model: Short FBH-W Series Spring Applied, Hydraulically-Released Multiple Plate Brake for Wet Operation. Installation. Position 1-off gasket (5) over male pilot on brake housing (4). Locate brake shaft (1) and secure brake in position using 2-off ½” UNC mounting bolts in the through mounting (fixing) holes provided. Connect hydraulic pressure supply to brake pressure inlet port. Ensure that the hydraulic pressure is set to the required level up to a maximum of 3000 psi (200 bar) and check that the brake disengages and re-engages correctly. Maintenance. The brake is required to be kept in good working order and must be included in the planned maintenance programme for the equipment to which the brake is installed. This must include torque testing together with inspection and replacement of the working parts such as friction plates (3 & 6) and, springs (22 & 23). The frequency of inspection depends on the duty demanded of the brake. Dismantling (and dis-assembly). To remove brake from its installed position, reverse procedure previously described in the Installation instructions. Place the complete brake assembly on a clean, dry workbench. Remove external gaskets (5) as necessary. REFER TO DIAGRAMS FOR THE FOLLOWING. 1) Supporting brake on face ‘A’, remove the six socket head cap screws (SHCS) and washers (items 13 & 14) in equal increments to ensure the spring pressure within the brake is reduced gradually and evenly. Alternatively, if a press is available, the cylinder housing (8) can be restrained on face ‘B’ while removing the six SHCS and washers (13 & 14). The brake assembly can now be fully dismantled and the parts examined. 2) Remove cylinder housing (8) and piston (9) subassembly and dismantle if required, removing ‘O’ ring seals (15 & 17) and backing rings (16 & 18) as necessary. 3) Remove gasket (7) from housing (2). 4) Remove friction plates (3 & 6) and pressure plate (4). 5) Remove 2-off dowel pins (19). 6) Remove springs (22 & 23). Note: See chart on page 4 for spring arrangement and quantities for the particular brake model used. 7) Should it be necessary to replace ball bearing (10) or shaft seal (12), reverse remainder of brake subassembly, supporting on face ‘C’ of housing (2). 8) Remove internal retaining ring (11).

9) Using arbor press or similar to break ‘Loctite’ seal, remove brake shaft (1) from housing (2) and lay aside. 10) Reverse housing (2) and press out ball bearing (10). Shaft seal (12) can also be removed if necessary. Examination. All components can now be examined and inspected, paying particular attention to the following. 1) Inspect friction plates (3 & 6) and friction surface on pressure plate (4) for wear or damage. 2) Examine friction plates (3) and brake shaft (1) for wear or damage to the splines. 3) Examine input and output splines of brake shaft (1) for wear or damage. 4) Examine compression springs (22 & 23) for damage or fatigue. 5) Check ball bearing (10) for axial float or wear. 6) Examine ‘O’ ring seals (15 & 17) and backing rings (16 & 18) for damage. OBTAIN REPLACEMENT PARTS AS REQUIRED. Assembly. Clean all parts thoroughly. Reverse procedure previously outlined in Dismantling instructions taking particular care with. a) Assembly of shaft seal (12). b) Assembly of bearing (10). c) Quantity and orientation of springs (22 & 23). Note: See chart on back page for spring quantities and arrangement for the particular brake model used. d) Assembly sequence of friction plates (3 & 6).-See diagram. 1) Lightly lubricate rotary shaft seal (12) and assemble to housing (2) taking care not to damage seal lip. 2) Apply ring of Loctite 641 or equivalent adhesive to full circumference of housing (2) bearing recess adjacent to shoulder. Apply complete coverage of Loctite 641 to outside diameter of bearing (10) and assemble fully in housing (2), retaining with internal retaining ring (11). Remove excess adhesive with a clean cloth. Secure and seal bearing inner ring to shaft (1) using Loctite 641 applied to bearing inner diameter. Remove any excess adhesive with a clean cloth. 3) Assemble correct quantity of springs (22 & 23) in orientation required.

Installation and Maintenance Instructions Model: Short FBH-W Series Spring Applied, Hydraulically-Released Multiple Plate Brake for Wet Operation. 4) Lubricate ‘O’ ring seals (15 & 17) with Molykote 55M (or equivalent) silicon grease and assemble together with backing rings (16 & 18) to piston (9). To ensure correct brake operation, it is important that the backing rings are assembled opposite to the pressurised side of piston (9). 5) Correctly orientate piston (9) aligning spaces with the two dowel pin holes and, assemble into cylinder housing (8) taking care not to damage seals and carefully lay aside. 6) Locate 2-off pins (19) in housing (2) followed by pressure plate (4) and friction plates i.e. an inner (3) followed by an outer (6) in correct sequence. 7) Position gasket (7) in correct orientation.

8) Align two holes in cylinder with dowel pins (19) and assemble piston & cylinder sub-assembly to remainder of brake securing with 6-off SHCS and washers (13 & 14). Torque tighten to 55 lbF.ft (75 Nm). Note: The use of a suitable press (hydraulic or arbor) pressing down on cylinder end face ‘B’ will ease assembly of the SHCS (13). Note: If new friction plates have been assembled, it is recommended that the friction faces are “bedded in” to help ensure stable torque performance.

INTRODUCTION This manual is a step-by-step guide to assembly and disassembly of torque-hub units. It is designed for the customer or shop mechanic who is repairing a particular model of torque-hub final drive. Users of this manual should note that each part mentioned is followed by an indentification number enclosed in parentheses. These part numbers may be referred to in the Parts List section of this manual and on the cross-sectional view of this unit. A print of each tool discussed in this manual is shown in the Tooling section. Users should familiarize themselves with the procedures for roll and leak testing and bolt tightening and torquing found on the following two pages before getting started. This manual includes the following sections. 1. Roll and Leak Testing Procedures 2. Bolt Tightening and Torquing Procedures 3. Disassembly Procedures 4. Sub-Assembly Procedures 5. Main Assembly Procedure 6. Drawings of all Essential Tools 7. Parts List 8. Cross-Sectional View of the Unit

SAFETY

Standard safety practices should be followed during the disassembly and assembly procedures described. Safety glasses and safety shoes should be worn. Heavy, heat resistant gloves should be used when heated components are handled. Be especially alert when you see the word CAUTION. This indicates that a particular operation could cause personal injury if not performed properly or if certain safety procedures are not followed.

I

ROLL and LEAK TESTING Torque-hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit’s gears and sealants are working properly. The following information briefly outlines what to look for when performing these tests.

THE ROLL TEST

The purpose of a roll test is to determine if the unit’s gears are rotating freely and properly. You should be able to rotate the gears in your unit by applying a constant force to the roll checker. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for proper installation or defects. Some gear packages roll with more difficulty than others. Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency.

THE LEAK TEST

The purpose of a leak test is to make sure that the unit is air tight. You can tell if your unit has a leak if the pressure gauge reading on your air checker starts to fall once the unit has been pressurized. Leaks will most likely occur at the main seal or wherever “O” rings or gaskits are located. The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where “O” rings or gaskits meet the exterior of the unit then checking for air bubbles. If a leak is detected in a seal, “O” ring, or gaskit, the part must be replaced.

II

TIGHTENING and TORQUING BOLTS

If an air impact wrench is used to tighten bolts, extreme care should be taken to insure that bolts are not tightened beyond their indicated torque specification. Never use an impact wrench to tighten shoulder bolts, all shoulder bolts should be tightened by hand.

The following steps tightening and torquing in a bolt circle.

describe the proper procedure for bolts or socket head cap screws

1. Tighten (but do not torque) bolt “A” until snug.

2. Go to the opposite side of the bolt circle and tighten bolt “B” until equally snug.

3. Continue around the bolt circle and tighten the remaining bolts.

4. Now use a torque wrench to apply the specified torque to bolt “A”

5. Continue around the bolt circle and apply an equal torque to the remaining bolts.

III

MAIN DISASSEMBLY 1. Remove pipe plug (15) from cover(6) and drain the oil from the unit.

2. Roll test the unit in both clockwise and counterclockwise directions. Perform the same number of turns in each direction as the ratio of the unit. The ratio number is the same as the last two digits in the model number found on the ID tag of the unit.

3. Leak test the unit at a pressure of 5 psi for 2-3 minutes.

4. Remove all 24 grade 8 bolts(16) from cover(6).

1

5. Lift cover(6) off of hub(1G) and remove “O” ring(5) from the counterbore in the cover. Discard the “O” ring.

6. Remove small thrustwasher(7) from the counterbore in the center hole in cover(6).

7. Remove large thrust washer(14), thrust bearing(13), and large thrust washer(12) from the raised inside circular edge of cover(6).

8. Remove input gear(8) from mesh with the planet gears in first stage carrier assembly(3).

9. Lift out first stage carrier assembly(3).

2

10. Remove small thrust washer(9) from the top of second stage sun gear(11).

11. Remove thrust bearing carrier(10), large thrust washer(14), thrust bearing(13), and large thrust washer(12) from the counterbore of second stage carrier assembly(2).

12. Remove second stage sun gear(11) from mesh with second stage carrier assembly(2).

13. Lift out ring gear(4).

14. Remove “O” ring(5) from the counterbore in hub(1G) and discard.

3

15. Lift out second stage carrier assembly(2) from mesh with output shaft(1A).

16. Using retaining ring pliers, remove retaining ring(1L) from groove around the outside of output shaft (1A). CAUTION: Safety glasses should be worn during this procedure.

17. With a screwdriver or chisel and hammer, straighten out the tang on lockwasher(1J) which has been bent into the notch on locknut(1K).

18. Using an AN-18 locknut wrench (tool no T-156766), loosen locknuts (1K). Remove the locknut from output shaft(lA) and discard. NOTE: The output shaft must be held securely enough to resist turning when the locknut is loosened.

19. Remove lockwasher(1J) and tanged washer(1H) from output shaft(1A). Discard the lockwasher.

4

20. Raise hub(1G) above your work surface and support it from underneath in a manner that will allow output shaft(1A) to fall through the bottom. Press the output shaft out of the hub. The output shaft will come out with bearing cone (1D) attached and seal(1B). Discard the seal.

21. Remove bearing cone (1D) from output shaft(lA).

22. Lift bearing cone(1F) out hub(1G).

of

23. Using a soft punch and hammer, remove bearing cups (1E) and (1C) from hub(1G). Be very careful not to strike the counterbores of the hub where these cups are located when using the punch.

24. Remove all four pipe plugs (1M), (1N), and (1P) from hub(1G).

25. At this point the main disassembly is complete.

5

FIRST STAGE CARRIER DISASSEMBLY

1. Locate dowel pin(3D) which holds planes shaft(3E) in carrier housing (3A).

2. Drive the dowel pin(3D) down into planes shaft(3E) until it bottoms against the carrier housing. If the dowel pin is not completely driven into the planet shaft, damage to the carrier could occur when the shaft is removed.

3. Remove planet shaft(3E) from carrier housing(3A). The four thrust washers(3B) an d planet gear(3F) will slide off.

4. Using an alignment punch and hammer, drive dowel pin(3D) ou t through the end of the dowel pin hole in planet shaft(3E) that it originally went into.

6

5. Remove needle rollers(3C) from inside planet gear(3F).

6. Repeat steps 1-5 to remove the two remaining planet gears.

7. At this point the first stage carrier disassembly is complete.

7

SECOND STAGE CARRIER DISASSEMBLY

1. Locate dowel pin(2G) which holds planet shaft(2E) in carrier housing (2A).

2. Drive dowel pin(2G) down into planets shaft(2E) until it bottoms against the carrier housing. If the dowel pin is not completely driven into the planet shaft, damage to the carrier could occur when the shaft is removed.

3. Remove planet shaft(2E) from carrier housing(2A). The four thrust washers(2B) an d planet gear(2F) will slide off.

4. Using an alignment punch and hammer, drive dowel pin(2G) ou t through the end of the dowel pin hole in planet shaft(2E) that it originally went into.

8

5. Remove needle rollers(2C) an d spacer(2D) from planes inside gear(2f)

6. Repeat steps 1-5 to remove the two remaining planets gears.

7. At this point the second stage carrier disassembly is complete.

9

FIRST STAGE CARRIER SUB-ASSEMBLY

1. Apply grease to the inside of one first stage carrier planes gear(3F).

2. Line the inside of planet gear (3F) with 19 needle rollers(3C).

3.Stand first stage carrier housing(3A) in an upright position.

4. Insert a planet shaft(3E) into one of the planet shaft roles which has a dowel pin hole on carrier housing(3A). The end of the planet shaft that does not have the dowel pin hole should be inserted into the carrier housing first.

NOTE: One end of the dowel pin hole on the planet shaft has a chamfer or gradual slope. This end should be up to allow easy alignment.

10

5. Place two thrust washers(3B) onto the end of planet shaft(3E) which has been inserted through the planet shaft hole in carrier housing(3A). NOTE: Grease or petroleum jelly may be used to hold the washers together and in place on the planet shaft.

6. Following the thrust washers place planet gear (3F), with needle rollers, onto planet shaft (3E).

7. Following the planet gear, place two more thrust washers(3B) onto planet shaft(3E). NOTE: Grease or petroleum jelly may be used to hold the washers together and in place on the planet shaft.

8. Now insert planet shaft(3E) through the opposite planet shaft hole on carrier housing(3A).

9. Using an alignment puch or similar tool, align the dowel pin holes on carrier housing(3A) an d planet shaft (3E).

11

10. If you examine a dowel pin (3D) carefully, you will notice that one end is smaller than the other. Drive this end of the dowel pin (3D) down into the aligned dowel pin holes. It should be driven to just below (1/10 in.) the surface of the carrier housing.

ll. Repeat the procedure in steps 1-10 for installation of the two remaining first stage planes gears(3F).

l2. At this point the first stage carrier sub-assembly is complete.

12

SECOND STAGE CARRIER SUB-ASSEMBLY

1. Apply grease to the inside of one second stage planet gear(2F).

2. Line one half of planet gear(2F) with 18 needle rollers(2C).

3. Place one spacer(2D) inside planet gear(2F) so that it rests on top of the needle rollers (2C).

4. Line the remaining half of planet gear(2F) with 18 needle rollers(2C).

13

5. Stand second stage carrier housing(2A) in an upright position.

6. Insert planet shaft(2E) into a planet shaft hole that does not have a dowel pin hole on carrier housing (2A). The end of the planet shaft with the dowel pin hole should be inserted into the carrier housing first.

NOTE: One end of the dowel pin hole on the planet shaft has a chamfer or gradual slope. This end should be up to allow easy alignment.

7. Place two thrust washers(2B) onto the end of the planet shaft which has been inserted through the planet shaft hole. NOTE: Grease or petroleum jelly may be used to hold the washers together and in place on the planet shaft.

8. Following the thrust washers, place planet gear(2F), with needle rollers, onto planes shaft(2E).

14

9. Following the planet gear, place two more thrust washers(2b) unto planet shaft(2E). NOTE: Grease or petroleum jelly may be used to hold the washers together and in place on the planet shaft.

10. Now insert planet shaft(2E) through the opposite planet shaft hole on carrier housing(2A).

11. Using an alignment punch or similar tool, align the dowel pin holes on the carrier housing and planet shaft.

12. If you examine a dowel pin(2G) carefully, you will notice that one end is smaller than the other. Drive this end of dowel pin(2G) down into the aligned dowel pin holes. It should be driven to just below (1/10 in.) the surface of the carrier housing.

13. Repeat the procedure in steps 1-12 for installation of the two remaining second stage planet gears(2F).

14. At this point the second stage carrier sub-assembly is complete.

15

HUB-SHAFT SUB-ASSEMBLY

1. Apply a light coat of “NeverSeize” to the four hub pipe plugs (1M), (1N), and (1P). Note: Pipe plug(1P) is a magnetic plug.

2. With hub(lG) standing on its large diameter end, tighten pipe plugs(1M) into the two pipe plug holes nearest the small diameter end of hub(1g). NOTE: Notice that pipe plugs(lM) ar e much smaller than pipe plugs (1N) and (1P).

3. Turn hub(1G) over so that it rests on its small diameter end and the two pipe plug holes nearest the hub’s large diameter and are facing you. Tighten magnetic pipe plug(1P) into the right-hand pipe plug hole.

4. Mark the location of magnetic pipe plug(1P) so that it may be aligned with the pipe plug hole in cover(6) in a later step.

16

5. Install pipe plug(1N) into the left-hand pipe plug hole nearest the large diameter end of hub (1G).

6. With hub(1G) still standing on its large diameter end, press bearing cup(1C) into the small diameter end of hub(1G) usina a bearing cup pressing fixture (tool no.T- 156792). NOTE: Make sure that the cup sits square with the counterbore of the hub before pressing.

7. Turn hub(1G) over so that it rests on its small diameter end. Press bearing cup(1E) down into hub(lG) using a bearing cup pressing fixture (tool no. T-130717). NOTE: Make sure that the cup sits square with the counterbore of the hub before pressing.

8. Spray the cone(1D) with oil.

inside

of

bearing

9. Press bearing cone(1D) onto output shaft(1A) using a bearing cone pressing fixture (tool no.T-158049).

17

10. With small diameter end down, lower hub(1G) onto output shaft(1A).

11. Spray the cone(1F) with oil.

inside

of

bearing

12. Press bearing cone(1F) onto output shaft(1A) using a bearing cone pressing fixture (tool no. T146588). Reduce the pressure applied to the bearing cone and press the cone again. This time rotate the hub in both clockwise and counterclockwise directions while pressing. Stop pressing when the hub starts to resist the rotation.

13. Now measure the initial rolling torque of hub(1G). To do this, follow steps a-d.

a) Tighten a bolt into one of the bolt holes on the hub. The bolt used should be one that fits the hole.

18

b) Place a torque wrench on the bolt so that the arm of the wrench lines up on a tangent to the circumference of the hub as shown in figure 1.

c) Keeping the wrench in position at all times, use the of the wrench to guide the around in one rotation.

this arm hub

d) Read the gauge on the torque wrench. The initial rolling torque should be 25-30 in.-lbs. Measure the rolling torque several times to insure an accurate reading.

NOTE: If the initial rolling torque is less than 25 in.-lbs., apply more pressure to bearing cone(1F). If the initial rolling torque is higher than 30 in.-lbs., strike the top of output shaft(1A) with a soft face hammer to release the load on the shaft, then repeat steps 13b - 13d.

14. Place tanged Fwasher(1H) onto output shaft(1A).

19

Rolling Torque Procedure

THE CORRECT READING CAN ONLY BE MADE IF THE TORQUE WRENCH IS PULLED SLOWLY (APPROX. 3.5 R.P.M.) AND SMOOTHLY TOWARDS YOU.

Figure 1. 20

15. Place lockwasher(1J) onto output shaft(1A). NOTE: Notice that lockwasher(1J) has tangs and tanged washer(1H) does not.

16. Spray the inside of locknut(1K) and the exposed sides of output shaft(1A) with Locquic Primer T. Allow two minutes drying time.

17. Apply Loctite 277 Adhesive/ Sealant to the second screwthread from the bottom of locknut(1K). NOTE: The bottom of locknut(1K) has a chamfered or inward sloping edge.

NOTE: Loctite 277 is an anaerobic adhesive. Once it has been removed from air, it sets. Therefore, once the locknut has been placed on the output shaft, it must be torqued immediately or the adhesive will make it difficult to turn.

18. Place locknut(1K) onto output shaft(1A) and screw into place.

21

19. Using an AN-18 locknut wrench (tool no. T-156766) and a torque wrench, apply 225 ft.-lbs. of torque to locknut(1K).

NOTE: One tang on lockwasher(1J) must line up directly with one notch on locknut(1K). If one tang does not line up with a locknut notch, apply sufficient increased torque to the locknut until it does. Never loosen the locknut.

20. Measure of hub(1G) described in final rolling 35-60 in.-lbs.

the final rolling torque using the same manner steps 13a - 13d. The torque should measure

NOTE: Remove the bolt from the hub.

21. Bend the aligned tang on lockwasher(1J) up into the notch on locknut(1K).

22. Using a center punch and hammer, stake locknut(1K) in four equally spaced positions around the circumference of the locknut and at a distance of 1/8 in. from the inside edge of the locknut. 23. At this point the hub-shaft subassembly is complete.

22

MAIN ASSEMBLY

1. Turn hub(1G) over so that it rests on its large diameter end. Spray oil on all exposed surfaces inside the hub while turning output shaft(1A).

2. Spray the inside of seal(1B) with oil. NOTE: The open face of the seal may have a waved surface. This is an intentional design used to keep dirt out.

3. Press seal(1B) into the small diameter end of hub (1G) using a seal pressing fixture (tool no.T-156799).

4. Turn hub(1G) over once again so that it rests on its small diameter end. Using retaining ring pliers, insert retaining ring(1L) into the groove on output shaft(1A). CAUTION: Saftey glasses should be worn during this procedure.

23

5. Place second stage carrier assembly(2) , with spline connections down, into hub(1G) so that the carrier’s spline connections mesh with the spline connections on output shaft (1A).

6. Spray oil on all exposed surfaces inside hub(1G).

7. Grease “O” ring(5).

8. Place “O” ring(5) into the counterbore of hub(1G). Make sure that the counterbore is oil free before installing “O” ring. CAUTION: Beware of sharp edges and burrs in the counterbore while installing the “O” ring.

NOTE: “O” rings may be stretched to fit the counterbore. If an “O” ring has been stretched too much, simply squeeze the “O” ring together bit by bit as you place it around the counterbore. It can be made to fit exactly.

24

9. Spary oil on the inside of ring gear(4).

10. Place ring gear(4) with small diameter end down, into hub(lG) so that it fits over second stage carrier assembly(2).

11. Place second stage sun gear(11), with large diameter end down, into mesh with the planet gears of the second stage carrier assembly(2).

l2. Place large thrust washer(14), thrust bearing(13) , and large thrust washer(12) in that order into the counterbore of second stage carrier assembly(2). NOTE: Notice that thrust washer(14) is much thicker than thrust washer(12).

13. Place thrust bearing carrier (10), with small diameter end down, into the counterbore of second stage carrier assembly(2). It should fit over the thrust bearing set(12, 13, 14) described in step 12.

25

first stage carrier 14. Place assembly(3) , with spline connections down, into mesh with the second stage sun gear(ll) and the ring gear(4).

15. Place small thrust washer(9) on top of second stage sun gear(ll).

16. Place input gear(8) , with small diameter end down, into mesh with the planet gears of first stage carrier assembly(3). The input gear should be centered on the small thrust washer(9).

17. Set cover(6) down on its small diameter end.

18. Grease one side of large thrust washer(12), thrust bearing(13) , and large thrust washer(14) and place them greased side down in that order over the raised inside circular edge of cover(6). NOTE: Notice that thrust washer(14) is much thicker that thrust washer (12).

26

19. Grease small thrust washer(7) and place it in the counterbore of the center hole in cover(6).

20. Grease “O” ring(5) and place it around the counterbore in cover(6). CAUTION: Beware of sharp edges and stalling the “O” ring.

NOTE: “O” rings may be stretched to fit the counterbore. If an “O” ring has been stretched too much, simply squeeze the “O” ring together bit by bit as you place it around the counterbore. It can be made to fit exactly.

21. Place with large cover(6) , diameter end down, on top of ring gear(4) so that the cover’s pipe plug hole aligns with the magnetic pipe plug hole in hub(lG) according to figure 2.

27

Pipe Plug Timing

This figure shows the most common pipe plug timing for this series. Pipe plug timings may vary among units with different model numbers. Refer to an original assembly print for your particular unit to determine its correct pipe plug timing.

Figure 2.

22. Place the 24 grade 8 into cover(6) and tighten.

bolts(16)

23. Using a torque wrench, apply 3545 ft.-lbs of torque to each grade 8 bolt (16).

28

24. Apply a light coat of “NeverSeize” to pipe plug(15).

25. Tighthen pipe plug(15) into the pipe plug hole in cover(6).

26. Roll test the unit in both clockwise and counterclockwise directions. Perform the same number of turns in each direction as the ratio of the unit. The ratio number is the same as the last two digits in the model number found on the ID tag of the unit.

27. Leak test the unit at a pressure of 5 psi for 2-3 minutes.

28. At this point the main assembly complete.

29

TOOLING The following specialized tools are used in the assembly of this unit. The tool diagrams included in this manual are intended for the customer who may wish to have a tool made. All tools must be made from mild steel. All dimensions are given in inches. OPTIONAL: In order to improve tool life, tools may be carborized and hardened. If this is done, however, the tools must be ground on all surfaces labeled with a “G” on the tool diagram.

1. TOOL NO. T-130717 BEARING CUP PRESSING FIXTURE for CUP(1E) 2. TOOL NO. T-156792 BEARING CUP PRESSING FIXTURE for CUP(1C) 3. TOOL NO. T-158049 BEARING CONE PRESSING FIXTURE for CONE(1D) 4. TOOL NO. T-146588 BEARING CONE PRESSING FIXTURE for CONE(1F) 5. TOOL NO. T-156766 AN-18 LOCKNUT WRENCH 6. TOOL NO. T-156799 SEAL PRESSING FIXTURE

30

1 3

T-130717 SCALE: 3/4 ONE PIECE BEARING CUP PRESSING FIXTURE for CUP(1E)

2 3

T-156792 SCALE: 3/4 BEARING CUP PRESSING FIXTURE for CUP(1C)

3 3

T-158049 SCALE: 3/4 ONE PIECE BEARING CONE PRESSING FIXTURE for CONE(1D)

4 3

T-146588 SCALE: full ONE PIECE BEARING CONE PRESSING FIXTURE for CONE(1F)

5 3

T-156766 SCALE: 2/3 ONE PIECE AN-18 LOCKNUT WRENCH USE 3/4 in. DRIVE SOCKET

6 3

T-156799 SEAL PRESSING FIXTURE

SCALE: 2/3

PARTS LIST ITEM

QUANTITY

DESCRIPTION

1

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1

hub-spindle sub-assembly output shaft seal bearing cup bearing cone bearing cup bearing cone hub tanged washer lockwasher locknut retaining ring pipe plug pipe plug magnetic pipe plug

1 12 108 3 3 3 3

second stage carrier sub-assembly second stage carrier thrust washer needle roller spacer planet shaft planet gear dowel pin

1 12 57 3 3 3

first stage carrier sub-assembly 1 first stage carrier thrust washer needle roller dowel pin planet shaft planet gear

1A 1B 1C 1D 1E 1F 1G 1H 1J 1K 1L 1M 1N 1P 2

1 2A 2B 2C 2D 2E 2F 2G

3

1 3A 3B 3C 3D 3E 3F

4 5 6 7 8 9

1 2 1 1 1 1

ring gear “O” ring cover thrust washer input gear thrust washer

37

ITEM

QUANTITY

DESCRIPTION

10 11 12 13 14 15 16 17 18

1 1 2 2 2 1 24 4 1

thrust bearing carrier second stage sun gear thrust washer thrust bearing thrust washer pipe plug bolt drive screw ID plate

38

9 3

CROSS-SECTIONAL VIEW of S6A

Instructions: Change of Rotation and Seal Replacement 13

(PGP500 Series)

12

11

4 5

6 13 9

12

10

9

7

6

5 4 3

2

8 1

Item 13 12 11 10 9 8 7 6 5 4 3 2 1

Quantity 4 4 1 1 2 1 1 2 2 2 2 1 1

Description Capscrew Washer Housing, Pec Housing, Gear Sea, O-R Gear, driven Gear, drive Thrblk Channel Seal Seal, bk-up Pin, dowel Housing, sec Lip seal

3

Note: Before disassembling ensure that the unit, bench and tools are thoroughly clean. Disassembly Instructions: 1. Where applicable, remove the drive coupling from the drive shaft using a suitable puller. The coupling must not be levered or hammered as this may cause internal pump damage. 2. If the pump has a keyed shaft, remove the key from the shaft. Lightly stone any burrs that may be on the shaft to prevent any damage to the seal during disassembly. 3. Clamp the pump in a vise using the mounting flange (2), with the drive shaft pointing down. Do not clamp on the machined pilot ring. 4. Scribe a line across the shaft end cover (2), gear housing (10) and port end cover (11). This will ensure proper alignment during reassembly. 5. Remove all the mounting bolts (13) and washers (12) from the assembly. 6. Remove the rear port end cover (11). 7. Lift the gear housing (10) off of the shaft end cover (2), tapping the housing with a soft mallet, if necessary. 8. Remove the rear bushing block (6) noting the orientation of the channel seal (5). 9. Carefully remove the gears by pushing up on the drive shaft (7). Remove the front bushing block (6) noting its orientation.

Change of Rotation Instructions: These instructions are intended for use in changing the rotation of a single section PGP500 series gear pump. Reassembly Instructions: 1. Rotate front bushing block (6) 180° from original position and place on shaft end cover (2). Make sure the backup seals (4) and channel seals (5) are seated properly. Parker Hannifin Corporation Gear Pump Division 1775 Logan Avenue Youngstown, Ohio 44501 Tel: (330) 746-8011 Fax : (330) 746-1148 http://www.parker.com/gearpump

2. Seat O-rings (9) in the machined groove and rotate housing (10) 180° around the shaft axis and place onto shaft end cover (2). Readjust location of dowel pins (3) if pulled out at disassembly. Note from Disassembly Step 4 that the line on the housing (10) and cover (2) should now be on opposite sides. 3. Slide the drive shaft gear (7) through the gear housing, bushing, and shaft seal. Be careful not to damage the shaft seal. Slide the driven gear (8) through the gear housing and into the bushing. 4. Rotate rear bushing block (6) 180° from original position and place on gears. Make sure the backup seals (4) and channel seals (5) are seated properly. 5. From its original position, rotate the port end cover (11) 180° around the shaft axis and position it over the gear housing. 6. Replace the washers and bolts into the unit. Torque bolts in a diagonal pattern. Dry assembly torques are given in Table 1. Do not over torque. 7. Rotate drive shaft with a small wrench to check for any binding.

Table 1: PGP/PGM500 series assembly torques SERIES ASSEMBLY TORQUE

PGP/PGM505

PGP/PGM511

PGP/PGM517

300 in-lbs(25 ft-lbs)

420 in-lbs (35 ft-lbs)

1000 in-lbs (83 ft-lbs)

Seal Replacement Instructions: These instructions are intended for use in changing the seals of a single PGP/PGM500 series gear pump or motor. Note the shape and orientation of all seals before and during removal. 1. If shaft end cover has a snap ring and outboard bearing, carefully remove. Insert a small diameter punch or screwdriver from inside the cover into the shaft seal opening. Gently tap to drive out the shaft seal. 2. Press the replacement shaft seal (1) squarely into the seal recess in the shaft end cover until it bottoms out. Lip seal garter spring faces in toward unit. Reinstall snap ring and bearing if applicable. Remount cover (2) in the vise. 3. Remove old plastic and rubber seals from the thrust blocks (6) and replace with new seals (4 & 5). Note seal orientation. Grease will help hold the seals in place. 4. Remove section seals (9) from housing (10) and replace with new o-rings. Light grease will help hold the seals in place. 5. Replace the front thrust block (6) on the shaft end cover (2) with seals facing down. For pumps, orient so middle of seal points to low pressure (inlet) side. 6. Position housing (10) on the cover (2) making sure the lines from Disassembly Step 4 match up (unless changing rotation). Tap in place with a soft mallet. 7. Replace the drive gear (7) and driven gear (8). If included in the seal kit, put the protective sleeve over the drive shaft before pushing through the shaft seal. 8. Replace the rear thrust block (6), seals facing up, with the middle of the seal pointing to the low pressure side. 9. Reinstall the port end cover (11) aligning the markings with the housing and shaft end cover. 10. Replace the four bolts and washers. Torque in a diagonal pattern according to the values in Table 1.

BULLETIN NO.GZ-MS-A066-3000E

MAG-170VP-3000E-1

SERVICE MANUAL

KAYABA INDUSTRY CO. LTD / KYB AMERICA LLC try again. Do not disassemble the Plunger Assy. (c) Remove the Relief Valve Assy (102-7), loosening the Plug (102-7-6). Do not loosen the Nut (102-7-16) and Set Screw (102-7-15). The setting pressure is changed by loosening the Nut and Set Screw. The Poppet Seat (102-7-3) will be remained in the Base Plate. Remove the Poppet Seat. (d) Remove the Plugs (102-17) and the Spring (102-13). While turning, pull the Spool (102-9) out. If difficulty is encountered, Tap the end of the Spool and insert it. Be sure the Spool slides smoothly, then try again. (e) Do not loosen the Plugs (102-8) and the Orifices (102-23) (102-22) if it is not necessary. (f) Loosen the Socket Head Bolts (300) evenly and pull the assembly of the Case (101) and Base Plate (102-1) out of the Flange (210). If difficulty is encountered, tap the top of the Base Plate (102-1) and insert it, then try again. (g) Position the assembly of the Case and Base Plate Assy with shaft down. Loosen the Socket Head Bolts (120) evenly and remove the Base Plate (102-1) away with the caution not to have the Pins (128) stick. (h) Remove the Valve Plate (105), the Springs (129) (149), the O-Ring (122) (133) and the Pin (118) (128). Care must be taken during the process not damage the Valve Plate. 2. Brake Piston (a) Blow compressed air to the oil passage of the brake to remove the Brake Piston (125) from the Case. Pay full attention the Brake Piston may be ejected out. (b) Remove the O-Rings (130) (131) from the Brake Piston. Remove the Disk Plate (127) and Friction Plate (126). 3. Cylinder Block (a) Pull the Cylinder Block Assembly (104) (106) (107) (108) (114) (115) (116) (117) (119) out by holding the Retainer Plate (107) and the Cylinder Block. Care must be taken during the process not damage the Piston Shoe and Cylinder Block. (b) Mark the Piston Assy and Cylinder Block to identify the each position. Remove the Piston Assy (106) and Retainer Plate (107) from the Cylinder Block (104). (c) Remove the Retainer Holder (108) and Pins (119). (d) Press the Spring, using the press machine. Use a Snap Ring Pliers to remove the Snap Ring (114). Remove the Collar (115) (117) and the Spring (116) from the Cylinder Block. 4. Remove the Swash Plate (109). 5. Remove the Steel Balls (110), the Piston Assy (111) and the Spring (139) from the Case. The Steel Ball may be come with Swash Plate. 6. Remove the Shaft (103), the Ball Bearing (112)and the Oil Seal (121). 7. Gear Box (a) Remove the Plugs(226) and Drain the lubrication oil in the Gear Box. (b) Remove the Socket Head Bolts (208) and the Cover (224). Tap the Cover using plastic hammer to remove the Cover, because the Cover is sealed by liquid gasket. (c) Remove the Thrust Plate(s) (223). (d) Remove the Drive Gear (204) and the Holder A S/A (201). (e) Remove the Thrust Plate (205) and the Sun Gear B

Fill the Gear Box with lubricating oil, before and until the oil flows out of oil check port on the Cover. After confirming the sufficient oil level, tighten each plugs of the port. Air and water must be purged from the hydraulic system, otherwise the hydraulic components will be subject to failure from cavitation or lack of lubrication. The motor may be purged by operating for a while under no load with low speed. Check also that no air bubbles are present in the reservoir before beginning the operation. Make sure all connections are tight.

REPLACE SEALS Replace all seals in the motor section, if the accumulated operation period with the fluid temperature over 80 ℃ (176F) is reached 100 hours. Replace all seals in the Gear Box, if the accumulated operation period with the oil temperature over 90 ℃ (194F) is reached 100 hours.

HYDRAULIC FUID Initial Replacement Visual Inspection Performance Inspection

500 Hr. Every 500 Hr. Every 1000 Hr.

HYDRAULIC FILTER Initial Replacement Periodic Replacement

50 Hr. Every 250 Hr.

LUBRICATING OIL Initial Replacement Performance Inspection Periodic Replacement

100 ~ 250 Hr. Every 1000 Hr. Every 1000 ~ 1500 Hr.

MOTOR SECTION Internal Inspection and Seals Replacement Every 1000 Hr. Brake Disk Replacement Every 300,000 cycle

PREPARATION Before removing the motor from the installation, drain all oil inside, then cover the oil port area to prevent foreign particles from entering the motor. Before disassembling the motor, clean outside of the motor thoroughly. During disassembling, warn the parts to protect from damage.

DISASSEMBLY PROCEDURE 1. Base Plate (a) Position the motor with the piston motor side up. Loosen the Socket Head Bolts (102-6-4) evenly. Remove the Flange (102-6-1), Spring Seat (102-5), Spring (102-4) and Spring Seat (102-3). (b) While turning, pull the Plunger Assy (102-2) out. If difficulty is encountered, tap the end of the Plunger and insert it. Be sure the Plunger slides smoothly and then

1

06/25/1999


MAG-170VP-3000E-1

SERVICE MANUAL

KAYABA INDUSTRY CO. LTD / KYB AMERICA LLC (f) (i)

(g)

(h) (i) (j) (k) (l)

(206). Remove the Holder B S/A (202) and the Sun Gear C (208). Loosen the Socket Head Bolts (221) evenly and remove the Ring Gear (219) with the caution not to have the Pins (222) stick. Loosen the Socket Head Bolts (216) (217) and remove the Plate (218). Using a press, remove the Holder C S/A (203) with the caution not to have the Pins (215) stick. Remove the Shim (214). Remove the Coupling (600). Press the Flange (210) out of the Housing (213). Using (-) screwdriver remove the Floating Seal (211) from the Housing. Press the Angular Bearings (212) out of the Housing. Using (-) screwdriver remove the another Floating Seal (211) from the Flange.

Pins project from the Flange by 26.5 – 27.5 mm. (l) Grease the Shim(s) (214) and put it on the bottom surface of the Holder C S/A (203). (m) Put the Holder C S/A (203) onto the Flange (210). The pins must be properly inserted into the Flange. (n) Apply “Locktite No. 271” on the thread surface of the Socket Head Bolts (216) and then evenly tighten them into the flange (210). (o) Tap the Pins (222) on the Housing (213) so that the Pins project from the top surface of the Flange by 17mm. (p) Put the O-Ring (220) into the Housing (213). (q) Put the Ring Gear (219) onto the Housing (213). Tighten the Socket Head Bolts (221) evenly. (r) Ensure the Snap Rings (209) and (207) are properly installed into the Sun Gear C (208) and Sun Gear B (206). Put the Sun Gear C into the Holder C S/A (203) and put the Holder B S/A (202) onto the Sun Gear C (208) and then put the Sun Gear B (206) into the Holder B S/A (202). (s) Grease the Thrust Plate (205) and put it on the bottom surface of the Holder A S/A (201). (t) Put the Holder A S/A (201) onto the Sun Gear B (206). (u) Put the Drive Gear (204) into the Sun Gears B and C. The Drive Gear must be properly engaged with the planetary gears of the Holder A S/A (201). (v) Measure the gap ( Hr ). Referring to the table-1below, choose the appropriate Thrust Plate (223) according to the gap ( Hr ) and put it onto the Drive Gear (204).

After disassembly, wash the parts with cleaning solvent. Sufficient rust prevention is necessary to store the parts.

ASSEMBLY PROCEDURE All parts must be thoroughly cleared and ensured there is no dust, damage or scratch prior to assembly. Seals and bearings must be replaced with new one. 1. Gear Box (a) Grease fully the Floating seals (211). Put the one of Floating Seal (211) into the Flange (210). (b) Put the other Floating Seal on the Floating seal already set on the Flange. Ensure the concentricity of these Floating Seals. (c) Press the inner race of the Angular Bearing (212) into the Flange (210). (d) Press the outer races of both Angular Bearings into the Housing (213) from both sides. (e) Put the Housing (213) on the Flange (210) quietly. (f) Press the inner race of the Angular Bearing remaining into the Flange (210). (g) Press the top of the inner race of the Angular Bearing (212) already installed into the Flange (210) with even thrust force of 3000kgf. While pressing, measure the gap ( H ). (h) Measure the gap ( h ) on the bottom surface of the Holder C S/A (203).

Holder C S/A (203)

(k)

Gap ( Hr ) 1.74 to 1.21 1.20 to 0.67 0.66 to 0.04 0.03 to -0.16 -0.17 to –0.41

(w)

h

t : Thickness of the Shim(s)

Shim(s) (214)

(i) (j)

Holder A S/A (201)

t > h - H

t H

Flange (210)

r H

(x) (y) Housing (213)

Calculate the shim thickness required ( t ). The Shim(s) (214) may be combined in order to assure that Height of the Shim(s) ( t ) is slightly greater than h - H. Press the Pins (215) into the Flange (210) so that the

(z)

2

Ring Gear (219)

Thrust Plate ( 223 ) 20941-62305 20941-62306 20941-62307 20941-62308 20941-62309 table-1

Degrease the contact surface of the Ring Gear (219) and the Cover (224). Apply uniformly the liquid gasket, “Three Bond 211” and then put the Cover onto the Ring Gear. Tighten the Socket Head Bolts (225). Tighten the Plugs (226) using Teflon tape. Position the Gear Box with the piston motor side up. Degrease the thread surface of the Socket Head Bolts (217) and thread hole of the Flange (210). Apply “ Locktite No.217” on the thread surface of the Socket Head bolts. Put the Plates (218) into the Flange (210) and tighten the Socket Head Bolts (217). Ensure the Pin (601) is completely inserted into the Coupling (600) and put the coupling onto the spline shaft of the Drive Gear (204). 06/25/1999


MAG-170VP-3000E-1

SERVICE MANUAL

KAYABA INDUSTRY CO. LTD / KYB AMERICA LLC 2. (a) (b)

(c)

(d)

(e)

(f)

(g) (h)

(i)

(j)

(k)

(l) 3. (a) (b) (c)

(d) (e)

(f)

(g)

(h)

(i)

Plunger Assy. Ensure the O-Ring (102-6-2) is put into the groove on the Cap Assy (102-6). Put both Caps (102-6) to the Base Plate (102) and tighten the Socket Head Bolts (102-6-4).

Motor Section Apply grease on the Oil Seal (121). Press into the Case (101). Ensure the Oil Seal was completely installed. Place the Springs (139) into the bores at the bottom of the Case (101). Apply grease on the sliding surfaces of the Piston Assys (111) and insert into the bores. Press the Ball Bearing (112) onto the Shaft (103). Insert the Shaft into the Case (101). Ensure the Shaft rotates smoothly. Apply working fluid on the Steel Balls (110) and the spherical hollows at the bottom of the Case (101). Place the Steel Balls into the hollows and the Swash Plate (109) into the Case (101). Place the Spring Seat (115), the Spring (116) and the Collar (117) into the Cylinder Block (104). Press the Spring and install the Snap Ring (114). Apply grease on the Pins (119) and insert the Pins into the Cylinder Block (104). Place the Retainer Holder (108) onto the Cylinder Block. Put all the Piston Assy (106) into the Retainer Plate (107) from the flat surface of the Retainer Plate. Apply the hydraulic fluid in the bores of the Cylinder Block (104) and on the spherical surface of the Retainer Holder (108). Insert the Piston Assys into the Cylinder Block. Apply the hydraulic fluid on the sliding surface of the Swash Plate (109) and the sliding surfaces of the shoes of the Piston Assys. Insert the Cylinder Block Assembly onto the Shaft (103). Submerge the Disk Plate (127) in the hydraulic fluid prior to the assembly. Place the Disk Plates and the Friction Plate (126) into the Case (101). Fit the D-Rings (130) (131) into the grooves of the Brake Piston (125) and apply grease on the sliding surface. Insert the Brake Piston into the Case so that the holes for the pins on the Brake Piston and Case align. Put the Springs (141) and (129) onto the Brake Piston. Base Plate Press the Ball Bearing (113) into the Base Plate (102). Insert the Pin (118) into the Valve Plate (105). Apply grease to the back of the Valve Plate. Place the Valve Plate onto the Base Plate with the bronze color side up. Apply grease on the O-Ring (122) and place it onto the Case (101). Place the O-Rings (133) onto the Case (101) without grease. Insert the Pins (128) into the Base Plate (102) with tapered side up. Place the Base Plate (102) onto the Case (101) with caution that any parts under the Base Plate should not drop. Tighten the Socket Head Bolts (120) and (300). Insert the Spool (102-9) ,Spring (102-13) and Spring Guide (102-16) into the Base Plate(102). Ensure the O-Rings (102-15) are installed into the Plugs (102-14) and (102-17), tighten the Plugs into the Base Plate. Make sure that there is the Poppet Seat (102-7-3) at the top of the Relief Valve. Apply grease onto the O-Rings of the Relief Valve. Insert the Relief Valve Assy (102-7) into the Base Plate (102) and Tighten. Insert the Plunger Assy (102-2) into the Base Plate (102). Place the Spring Seat (102-3), Spring (102-4), and another Spring Seat (102-5) onto each side of

3

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SERVICE MANUAL

KAYABA INDUSTRY CO. LTD / KYB AMERICA LLC

Replace parts in the following criterion when disassembling the motor. Handle each of parts with deliberation and take care not to damage them. Replace all seals when disassembling the motor, even though no damage is found on them.

Hydraulic Motor Section Item & Check Point

Allowable Limit

Piston Assy (106) (a) Deep score or roughness on the shoe. (b) Deep score or roughness on the reciprocating potion. (c) Large clearance between the Piston and Cylinder Block. (d) Play on the shoe ball portion. Cylinder Block (104) (a) Deep score or roughness on the sliding portion. (b) Deep score or roughness inside bore. (c) Large clearance between the Piston. (d) Large clearance between the Shaft spline. Valve Plate (105) (a) Roughness of the sliding portion or deep score caused by serious damage, seizure and partial wear. Retainer Plate (107) Retainer Holder (108) (a) Roughness of the sliding portion or deep score caused by serious damage, seizure and partial wear. Swash Plate (109) (a) Roughness of the sliding portion or deep score caused by serious damage, seizure and partial wear. (b) Deep score or roughness on the Steel Ball portion. (c) Depth of the Steel Ball portion. Shaft (103) (a) Deep lip mark, roughness or serious damage on the sliding portion for Oil Seal. (b) Excessive wear or breakage on the spline (c) Large clearance between the Cylinder Block spline hole. (d) Large clearance between the Coupling spline hole. Brake Piston (125) (a) Dimension (b) Roughness or serious damage on the sliding portion. Disk Plate (127) (a) Dimension (b) Serious damage or peeling. Ball Bearing (112), (113) (a) Serious damage on the races and Balls. (b) Discontinuous rotation Piston Assy (111) (a) Deep score or roughness on the shoe. (b) Deep score or roughness on the reciprocating potion. (c) Large clearance between the Piston and Flange Holder. (d) Play on the shoe ball portion. Plunger Assy (102-2) (a) Serious damage, roughness or deep score. (b) Large clearance between the Plunger and bore. Base Plate (102) (a) Serious damage, roughness or deep score on the bore. Spool (102-9) (a) Serious damage, roughness or deep score. (b) Large clearance between the Spool and bore. Relief Valve Assy (102-7) (a) Roughness or serious damage on the Free Piston sliding

4

Parts to be Replaced Cylinder Block Kit (B6)

0.8a 1.2a 0.060mm 0.40mm Cylinder Block Kit (B6) 0.8a 1.6a 0.060mm 38.749(pin dia.3.333) Valve Plate (105) 0.8a <0.02mm(scoring depth) Retainer Plate (107) Retainer Holder (108) 0.8a <0.02mm(scoring depth) 0.8a <0.02mm(scoring depth) 1.6a 14.5mm

Swash Plate (109) Steel Ball (110) if it is necessary.

Shaft (103) 1.6a <0.02mm(scoring depth) 47.380(pin dia.3.000 30.498(pin dia.3.33) Brake Kit (125) 45.7mm (Height) 2.5a Brake Kit (127) 3.2 (Thickness) Ball Bearing (112), (113)

Case Kit (B7) 1.6a 1.2a 0.040mm 1.0mm 0.8a <0.02mm(scoring depth) 0.060mm 0.8a <0.02mm(scoring depth)

Base Plate Kit (B5)

Base Plate Kit (B5) Base Plate Kit (B5)

0.8a 0.060mm <0.02mm(scoring depth)

Relief Valve Assy (B4)

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MAG-170VP-3000E-1

SERVICE MANUAL

KAYABA INDUSTRY CO. LTD / KYB AMERICA LLC portion or the Poppet seating portion.

5

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MAG-170VP-3000E-1

SERVICE MANUAL


6

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MAG-170VP-3000E-1

SERVICE MANUAL


7

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MAG-170VP-3000E-1

SERVICE MANUAL


8

06/25/1999

FKB Air Cleaner Smaller, Lightweight Alternative Two-Stage Air Cleaner Designed for horizontal installation The FKB family of two-stage air cleaners for medium dust conditions. T S Compared to other air cleaner U D styles, this new air cleaner family M delivers the performance of U I D competitive larger air cleaners in a E M compact, rugged design.

Mann & Hummel

With a heavy-duty plastic construction and non-metal filters, the air cleaner is lighter, more efficient and easier to install and replace than competing products. Another key design feature is the built-in mounting brackets. There's no need for additional mounting support.

Donaldson FKB05

Fleetguard/Nelson

FKB air cleaners are smaller in diameter compared to competitive brands with similar airflow.

The FKB’s plastic housing and durable construction enables its installation in all types of operating environments and temperature ranges from -40° to 82°C, operating in medium-dust conditions with engine air flow from 70 to 360 cfm.

The two stage design features a built-in pre-cleaner that separates up to 85% of airborne contaminants.

FKB air cleaners effectively reduce contaminants flowing into the air intake system, provide a high level of engine protection from harmful contaminants and increase engine performance and fuel efficiency. The air cleaner models ship with both the primary and safety filters.

FKB08

FKB06

FKB05

FKB04 Donaldson FKB air cleaners are protected internationally by patents, trademarks, and design registrations, both issued and pending.

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• Engine Air Cleaners, Accessories & Service Parts

www.donaldson.com/aircleaners

FKB Air Cleaner Built-in Mounting Brackets and Filter Indicator Port Easy to service with non-metal filters Applications • Off-road equipment operating in medium-dust conditions with engine airflow range of 70 to 360 cfm (2 to 10.3 m3/min)

Inlet M E D I U M D U S T

• Installs horizontally. Mounting the air cleaner directly to the engine is not recommended; excessive engine vibration can cause premature air cleaner structural failure Outlet

• Sustained temperature tolerance: -40º to 180°F / -40º to 82°C. Do not install next to components that exceed the maximum temperature (180ºF / 82ºC); like a turbocharger, muffler, exhaust pipe or other high temperature component

Features • Smaller in diameter compared to competitive brands with similar airflow

Filter changeout is a snap with minimal service clearance required

• Improved handling and maintenance: lighter and smaller, changing filters is a snap • Product design includes: - primary filter - safety filter - filter service indicator port • Improved filter disposal ease: no metal

Picture of the B080074 filters next to the B045008 model filters - each set is shipped with the air cleaner.

• Cover latch position allows for minimum service clearance and eases filter service • Mounting brackets built-in to air cleaner body eliminating need for mounting bands


Engine Air Cleaners, Accessories & Service Parts •

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FKB Air Cleaner Initial Airflow Restriction

When spec’ing an Air Cleaner . . .

CFM 6" H2O 8" H2O 10" H2O

Determine the airflow requirements of your engine, then find the corresponding cfm airflow in the table at r ight. The restriction numbers (shown in inches of water) indicate the approximate initial restriction T of each model air cleaner at that cfm. If S there are two air cleaner models that fit U D your parameters, choosing the one with the M lowest restriction will provide longest filter U I service life. When calculating total initial D restriction of the entire air intake system, E M include the restriction caused by ducting, elbows, pre-cleaners, etc.

70 116 155 265

84 137 185 315

95 154 207 360

Airflow Pattern “B”

Air Cleaner Model

Air in the side, out the end

B045008 B055006 B065045 B080074

FKB Specification Illustrations Side View Cover End View for B04, B05, and B06

Cover End View -B080074

D G

I B

E

JJ

E

C

A

K K

H

F A

M8 X 1.25 (2 - B04,B05 and B06)

M8 X 1.25 (4 - B080074)

FKB Specifications Body Dia. (A)

Inlet Dia. (B)

Outlet Dia. (C)

Housing Inlet Length Height (D) (E)

Outlet Length (F)

Inlet Location (G)

Center Service Line to Clear. Valve (H) (I) Weight

Restr. Tap Loc. (J)

Mounting Bracket Height (K)

B045008

5.22" 133mm

2.00" 51mm

2.00" 51mm

13.46" 342mm

3.88" 99mm

2.83" 72mm

1.60" 41mm

6.18" 157mm

7.44" 189mm

2.1 lb 1.0 kg

2.02" 52mm

2.82" 72mm

B055006

5.97" 152mm

2.50" 64mm

2.50" 64mm

15.89" 404mm

3.88" 99mm

2.88" 73mm

1.93" 49mm

6.18" 157mm

9.61" 244mm

3.2 lb 1.4 kg

2.05" 52mm

3.03" 77mm

B065045

7.09" 180mm

3.00" 76mm

3.00" 76mm

16.06" 408mm

4.72" 120mm

2.87" 73mm

2.07" 53mm

7.41" 188mm

9.50" 241mm

3.7 lb 1.7 kg

2.05" 52mm

3.54" 90mm

B080074

8.95" 227mm

4.00" 102mm

4.00" 102mm

16.75" 425mm

5.50" 140mm

2.40" 61mm

2.68" 68mm

7.78" 198mm

14.76" 375mm

5.52 lb 2.5 kg

1.57" 40mm

4.33" 110mm

Air Cleaner Models

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• Engine Air Cleaners, Accessories & Service Parts


FKB Air Cleaner Filter Service Indicator Port

Air Inlet Plastic Housing

Service Cover Outlet to Engine

Primary Filter Safety Filter inside

Cover latch position requires minimum space requirement for filter service

Vacuator™ Valve

Built-in Mounting Bracket

Safety Filter

FKB Service Parts


B045008

B065045

cover .................... ..................... ........ P606497 filter, primary ..................... ............... P604457 filter, safety..................... .................. P603729 Vacuator™ Valve..................... ........ P158914

cover .................. ...................... ......... P608592 filter, primary .................... ................ P609221 filter, safety................... .................... P608599 Vacuator™ Valve.................... ......... P158914

B055006

B080074

cover .................... ..................... ........ P609219 filter, primary ..................... ............... P609218 filter, safety..................... .................. P602427 Vacuator™ Valve..................... ........ P158914

cover .................. ...................... ......... P605731 filter, primary (metal liner) ............. P611190 filter, safety................... .................... P611189 Vacuator™ Valve.................... ......... P158914

Engine Air Cleaners, Accessories & Service Parts •

43

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