Hydro-Gear HGM-H Series Service And Repair Manual Download Page 31

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HEM

Headquartered in Sullivan, Illinois,

Hydro-Gear

is a world leader in the design,

manufacture, and service of quality hydrostatic

transaxles for the lawn and garden industry.

The mission of our company is to be recog-

nized by our customers and the industry as a

world-class supplier and the quality leader in

everything we do.
This Service and Repair Manual is designed

to provide information useful in servicing and

troubleshooting the Hydro-Gear HEM

High

Efficiency Motor.

Also included is a glossary of terms that are

frequently used throughout the industry and in

Hydro-Gear service publications. Understand-

ing terminology is very important!
It is necessary, and a good shop practice, that

your service area be equipped with the proper

tools and the technicians be supplied the lat-

est information available. All repair procedures

illustrated in this guide are suggested, but pre-

ferred methods of repair.

Repair procedures require that the HEM motor

be removed from the machine.

This is not a certification, test or study guide

for a certification test. If a technician is inter

ested in certification, they should contact an

agent representing the EETC (Equipment and

Engine Training Council) at (888) 406-1810 or

at [email protected]. Many distributors will be

hosting certification testing. These study guides

will cover most of the products and manufactur-

ers in our industry.
For more information about Hydro-Gear

or our

products, please contact your Central Service

Distributor.

FOREWORD

Summary of Contents for HGM-H Series

Page 1: ...BLN 0043 January 2018 HGM H Series Motor Service and Repair Manual ...

Page 2: ...me and Level 8 Fluid Change Procedure 8 Purge Procedure 9 Tear Down and Reassembly 10 How to Use This Manual 10 General Instructions 10 Tools 11 Torques 11 Hydraulic Motor Removal 12 Axle Hub Assembly 13 Brake Arm Assembly 14 Side Housing 15 Axle Shaft and Planetary Gear Set 16 Bearing and Motor Block Cap 17 Motor Block 18 Motor Shaft and Brake Disc 19 Brake Shaft and Cam 20 Screw Tightening Seque...

Page 3: ...eful in servicing and troubleshooting the Hydro Gear HGM H series motor Also included is a glossary of terms that are frequently used throughout the industry and in Hydro Gear service publications Understand ing terminology is very important It is necessary and a good shop practice that your service area be equipped with the proper tools and the mechanics be supplied the latest information availab...

Page 4: ... required the exterior of the motor will need to be thoroughly cleaned before beginning most procedures Do not wash the transaxle while it is hot Do not use a pressure washer to clean the unit GENERAL DESCRIPTION The HGM H series hydraulic motors are fixed displacement axial piston motors The motor is designed to convert hydraulic power into ro tational power at the axle shaft It operates at an in...

Page 5: ...k View Side View WHEEL HUB HUB NUT COVER BRAKE ARM HYDRAULIC HOUSING CAP FILL PORT OPTIONAL CASE DRAIN B PORT A PORT B PORT A PORT A B PORTS BRAKE ARM MOUNTING HOLE X 4 FILL PORT OPTIONAL CASE DRAIN BRAKE ARM WHEEL HUB HUB NUT COVER Figure 1 External Features ...

Page 6: ...ment 15 in3 rev 245 81 cc rev 18 in3 rev 294 97 cc rev Maximum Speed Continuous Intermittent 210 rpm 250 rpm 185 rpm 210 rpm Maximum Torque Peak Continuous Intermittent 6600 in lbf 75 N m 2700 in lbf 30 N m 4900 in lbf 75 N m 7900 in lbf 89 N m 3200 in lbf 36 N m 5900 in lbf 64 N m Maximum Oil Flow Continuous Intermittent 9 4 hp 7 KW 20 5 hp 15 4 kW Axle Shaft Diameter 1 375 in 34 925 mm Axle Shaf...

Page 7: ... or the performance of your job Never allow untrained or unauthorized person nel to service or repair the equipment Wear appropriate clothing Loose or hanging clothing or jewelry can be hazardous Use the appropriate safety equipment such as eye and hearing protection and safety toe and slip proof shoes Never use compressed air to clean debris from yourself or your clothing TOOL SAFETY Use the prop...

Page 8: ...lace belt pulley on vehicle pump assembly Page 8 Brake Partially Engaged Disengage Brake Replace damaged brake components Page 14 Unit Is Noisy Oil level low or contaminated oil Fill to proper level or change oil Page 8 Excessive loading Reduce vehicle loading Page 8 Loose parts Repair or replace loose parts Air trapped in hydraulic system Purge hydraulic system Page 9 Brake Partially Engaged Dise...

Page 9: ...after changing fluids FILTERS An inlet filter is required to insure that only clean fluid enter the system Refer to the vehicle manu facturer for approved filter replacement SERVICE AND MAINTENANCE EXTERNAL MAINTENANCE Regular external maintenance of the hydraulic motor should include the following 1 Check the vehicle operator s manual for the recommended load ratings Insure that the current appli...

Page 10: ...ting make sure the reservoir is at the proper oil level If it is not fill to the vehicle manufacturer s specifications The following procedures should be performed with the vehicle drive wheels off the ground then repeated under normal operating condi tions WARNING POTENTIAL FOR SERIOUS INJURY Certain procedures require the vehicle engine to be operated and the vehicle to be raised off of the grou...

Page 11: ... and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign material and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material The external surfaces should be cleaned before beginning any repairs Do not use a pressure washer to clean the transaxle Upon removal it is recommended that all seals O rings and gas...

Page 12: ...eep Breaker Bar Side Cutters Snips Needle Nose Pliers Large External Snap Ring Pliers Small Internal Snap Ring Pliers REQUIRED TORQUE VALUES Item Description Torque Operation 4 Screw Housing 280 340 in lbs 31 6 38 4 Nm All Housing Screws 10 Nut Axle Castlelated 275 350 ft lbs 372 9 474 5 Nm Hub 56 Nut Brake 600 800 in lbs 67 8 90 4 Nm Brake Shaft 80 Plug 9 16 16 Metal 110 170 in lbs 12 4 19 2 Nm O...

Page 13: ...f the transaxle The following procedures are pre sented in the order recommended for a complete tear down of the transaxle Do not disassemble the unit any far ther than necessary to accomplish the required repairs Reassembly is accomplished by per forming the Assembly portions of the procedures If the unit has been com pletely disassembled a summary of the assembly procedures in the order in which...

Page 14: ...axle shaft key 17 Inspection 1 Check all components for excessive wear or damage Replace if necessary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 When tightening the castle nut 10 refer to the table on page 11 for the required torque values NOTE As a general rule use the low end of the torque specification Once at the speci fied torque rotate castle nut clockwise to align...

Page 15: ...ning ring 60 4 Remove the brake handle 59 spring 82 and spring pin 83 5 Remove the spring spacer 81 and brake spacer 57 5 Remove the dowel pin 84 and the seal 58 Discard the seal NOTE Only remove the seal 58 and dowel pin 84 if damaged or worn or if doing a complete disassembly Inspection 1 Inspect all parts for wear or damage Re place as necessary Assembly 1 Reassemble all parts in the reverse or...

Page 16: ...embly 1 Reassemble all parts in the reverse order of disassembly 2 Apply a bead of sealant around the perim eter of the middle housing face See Seal ant Application Diagram on page 21 NOTE Remove all old sealant from the axle housing 1 and the middle housing 2 before applying new sealant 3 Align the side housing 2 with the main housing 1 Use care not to smear the seal ant bead 4 Install the twelve...

Page 17: ... shaft 16 and planetary assembly from the middle housing 2 5 Remove the axle retaining ring 26 axle shaft spacer 25 axle gear 24 planet gears 22 sun gear 23 and the carrier 20 NOTE The sun gear 23 and axle gear 24 are pressed as one piece in some models Figure 8a Inspection 1 Inspect all items of the planetary gear set for wear and or damage Assembly 1 Reassemble all parts in the reverse order of ...

Page 18: ...g 47 and washer 46 Discard the re taining ring 47 Inspection 1 Inspect the races of the thrust bearing 80 for wear or damage Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Install new o ring 6 and retaining ring 47 from seal kit 3 Place the thrust bearing assembly 45 so the thick race contacts the motor block pis tons 4 Install the seven housing screws 6 Refer to the screw t...

Page 19: ...ng 2 3 Disassemble the motor block assembly and inspect all parts Inspection 1 Inspect the pistons 43 piston seats 42 springs 41 and the motor cylinder block 40 of the motor block assembly for scratches and or wear Replace the motor block assembly if necessary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Apply a light coating of oil to all running sur faces to prevent scor...

Page 20: ...ecommended order 2 Remove the motor shaft 34 retaining ring 30 and gear 31 out of the middle housing 2 3 Remove the brake rotor 32 and the washer 33 4 Remove the inboard axle bearing 27 Inspection 1 Inspect for scratches and or damage to the brake rotor 32 3 Inspect the gear 31 and motor shaft 34 for wear or damage Assembly 1 Reassemble all parts in the reverse order of disassembly 2 ...

Page 21: ... the brake shaft 50 the splined cam 51 the puck cam 52 and brake puck 54 4 Remove the magnet screw 7 magnet 8 and dowel pin 53 NOTE Only remove the dowel pin 53 and magnet components 7 8 if damage is present Inspection 1 Inspect the puck 54 for excessive wear 2 Inspect all components for wear or dam age Assembly 1 Reassemble all parts in the reverse order of disassembly 2 When tightening the nut 5...

Page 22: ...HGM H 21 SCREW TIGHTENING SEQUENCE SEALANT PATH 1 2 3 12 10 8 6 4 11 9 7 5 7 5 2 3 6 1 4 Figure 13 Side Housing Bolt Sequence Figure 14 Motor Housing Cap Bolt Sequence Figure 15 Sealant Path ...

Page 23: ...h is not available please use the alternative procedure outlined in this document All parts need to be clean and free of lubrication Procedure 1 Engage machine parking brake 2 Remove nut cover 3 Remove existing nut 4 Install new nut to 50 ft lbs 5 Mark a point on the new nut and hub per Figure 16 Point A 6 Measure 2 nut flats or 120º per Figure 16 and mark hub Point B 7 Turn nut clockwise until ma...

Page 24: ... gear 23 onto the axle shaft 16 Install the bull gear 24 thrust spacer 25 and retaining ring 26 onto the axle shaft and set assembly aside Place the axle assembly into the main housing Install the ring gear 21 onto the axle shaft so that the teeth mesh with the planet gears and install the washer 15 and axle bearing 14 onto the axle shaft 16 Page 16 Note Make sure that two of the tabs on the outer...

Page 25: ...24 HGM H HGM H MOTOR EXPLODED VIEW ...

Page 26: ... Retaining Ring 27 Bearing Axle Inboard 30 Retaining Ring Motor Shaft 31 Gear 19T 32 Rotor Brake 33 Washer Motor Shaft 34 Shaft Motor 40 Motor Block Kit 16cc Cylinder 45 Thrust Bearing 46 Washer 47 Retaining Ring External 50 Shaft Brake 51 Splined Cam Brake 52 Cam Puck Brake 53 Pin Ground Dowel 54 Brake Puck 55 Washer Flat 63 X 1 0 X 125 56 Nut Brake 57 Spacer Brake 58 Seal Brake 59 Handle Brake A...

Page 27: ...e in the charge circuit Check Valve A valve whose primary function is to restrict flow in one direction Closed Loop A sealed and uninterrupted circulating path for fluid flow from the pump to the motor and back Decay Rate The ratio of pressure decay over time End Cap See Center Section Entrained Air A mechanically generated mixture of air bubbles having a tendency to separate from the liquid phase...

Page 28: ...ll of the components and allowing the air a path of escape Rated Flow The maximum flow that the power supply system is capable of maintaining at a specific operating pressure Scoring Scratches in the direction of motion of mechanical parts caused by abrasive contami nants Swash Plate A mechanical device used to control the displacement of the pump pistons in a fluid power system System Charge Chec...

Page 29: ...HEMTM Series Motor Service and Repair Manual BLN 0083 January 2018 ...

Page 30: ...Assembly After Complete Tear Down 17 HEM Exploded View 18 HEM Parts List 19 Glossary of Terms 20 SECTION PAGE Foreword 1 Description and Operation 2 4 Introduction 2 General Description 2 External Features HEM TM 3 Technical Specifications 4 Product Identification 4 Safety 5 Personal Safety 5 Tool Safety 5 Work Area Safety 5 Servicing Safety 5 Troubleshooting 6 Service and Maintenance 7 8 External...

Page 31: ...important It is necessary and a good shop practice that your service area be equipped with the proper tools and the technicians be supplied the lat est information available All repair procedures illustrated in this guide are suggested but pre ferred methods of repair Repair procedures require that the HEM motor be removed from the machine This is not a certification test or study guide for a cert...

Page 32: ... tinuous torque to the motor shaft Reversing the direction of the incoming pressurized fluid into the motor reverses the direction of the motor output rotation INTRODUCTION The purpose of this manual is to provide in formation useful in servicing the Hydro Gear HEM TM High Efficiency Motor This manual includes general descriptions technical specifications servicing and troubleshooting procedures S...

Page 33: ...HEMTM 3 EXTERNAL FEATURES Shaft Speed Sensor Optional Motor Housing End Cap Case Drain B Port A Port Figure 1 External Features ...

Page 34: ... 5 8 Straight Keyed long 3 4 Tapered 9 Tooth Spline with 16 32 Pitch 5 8 Straight Keyed 3 4 Tapered 9 Tooth Spline with 16 32 Pitch Output Speed Maximum Continuous Minimum Continuous Maximum Intermittent 3000 rpm 50 rpm 4200 rpm 3000 rpm 50 rpm 4200 rpm Weight Ib kg 7 3 1 7 3 1 Figure 2 Product Label Model Number HEM12AASCVXTXXX Serial Number 5 049 HE 10001 Assembled in USA Year Built Date Julian ...

Page 35: ... or the performance of your job Never allow untrained or unauthorized person nel to service or repair the equipment Wear appropriate clothing Loose or hanging clothing or jewelry can be hazardous Use the appropriate safety equipment such as eye and hearing protection and safety toe and slip proof shoes Never use compressed air to clean debris from yourself or your clothing TOOL SAFETY Use the prop...

Page 36: ...ssive loading Reduce machine loading Loose parts Repair or replace loose parts Air trapped in hydraulic sysytem Refer to machine manufacturer s recommendations for purging air from the system Unit Has No Low Power Engine speed low Adjust to correct setting Oil level low or contaminated oil Fill to proper level or change oil Excessive loading Reduce machine loading Air trapped in hydraulic sysytem ...

Page 37: ...ed oil change frequency In the event of oil contamination or hydrau lic system component failure a complete teardown and inspection of the HEM will be required SERVICE AND MAINTENANCE NOTE Any servicing dealer attempting a warranty repair must have prior ap proval before conducting maintenance of a Hydro Gear product unless the servicing dealer is a current Authorized Hydro Gear Service Center EXT...

Page 38: ...hine manufacturer s recommendations for purging air from the system Air creates inefficiency because its compres sion and expansion rate is higher than that of the oil Due to the effects air has on efficiency in hy drostatic drive applications it is critical that it is purged from the system The resulting symptoms in hydrostatic systems may be 1 Noisy operation 2 Lack of power or drive after short...

Page 39: ...e kept free of foreign material and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material The external surfaces should be cleaned before beginning any repairs It is best to not allow direct spray from a pressure washer to clean the motor Upon removal it is recommended that all seals O rings and gaskets be replaced During installation lightly lubricate al...

Page 40: ...ive Ratchet Large External Snap Ring Pliers Needle Nose Pliers T30 Torx 1 2 Open Ended Wrench Face Seal Driver Optional REQUIRED TORQUE VALUES Item Description Torque Operation 12 3 HFHCS 3 8 16 x 1 5 PATCH 470 530 in lbs 53 10 59 88 Nm End Cap Bolts 22 Screw Pan Head 1 4 20 x 75 100 130 in lbs 11 30 14 69 Nm Speed Sensor ...

Page 41: ...xternal parts of the HEM The following procedures are pre sented in the order recommended for a complete tear down of the HEM Do not disassemble the unit any farther than necessary to accomplish the required repairs Reassembly is accomplished by performing the Assembly portions of the procedures If the unit has been completely disassembled a summary of the assembly procedures in the order in which...

Page 42: ...21 3 Remove the shim 20 Inspection 1 Check all components for excessive wear or damage Replace if necessary Assembly 1 Reassemble all parts in the reverse order of disassembly 2 When tightening the screw 22 refer to the table on page 10 for the required torque values Figure 3 Speed Sensor Assembly 21 20 22 ...

Page 43: ... end cap 3 5 Remove the O ring 10 NOTE O ring 10 is located in the motor hous ing 1 Inspection 1 Inspect all parts for wear or damage Re place as necessary Assembly 1 Reassemble all parts in the reverse order of disas sembly 2 Install O Ring 10 into housing 1 3 Install the endcap 3 4 Install the three endcap screws 12 When tightening the screws 12 refer to the table on page 10 for the required tor...

Page 44: ...The running surface may show evidence of minor abrasion This will be normal wear If grooved scratched or smeared replace with a new cylinder block assembly 2 Inspect the pistons and springs for wear or damage 3 Inspect the piston seats Note Residual oil may cause the piston seats to remain stuck inside of the pis tons Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Install th...

Page 45: ... the swash plate 2 3 Remove the thrust bearing and races 8 Inspection 1 Inspect all components for wear or dam age Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Install the thrust bearing and races 8 into the swash plate 2 3 Install the swash plate 2 into the motor housing 1 Figure 6 Swash Plate And Thrust Bearing Assembly 2 1 8 ...

Page 46: ...d the internal retaining ring 16 6 Remove the shaft 13 Inspection 1 Inspect all components for wear or dam age Assembly 1 Reassemble all parts in the reverse order of disassembly 2 Install the shaft 13 into the motor housing 1 3 Install the internal retaining ring 16 4 Install the lip seal 17 5 Install the external retaining ring 16 and the face seal 18 into the housing 6 Install the woodruff key ...

Page 47: ...istons and springs into the cylinder block 7 See page 14 8 With the motor housing tiltled on its side install the cylinder block assembly 7 with the pistons contacting the thrust bearing See page 14 9 Install the o ring into the seat of the motor housing See page 13 ASSEMBLY AFTER A COMPLETE TEAR DOWN 10 Lubricate the mating surface of the cylinder block 7 to the end cap 3 with clean oil prior to ...

Page 48: ...ISO 46 GAL 705 Seal Kit 707 Driver Face Seal Seal kit contains item s 10 15 16 17 and 18 9 Tooth Spline with 16 32 Pitch 3 4 Tapered 5 8 Straight Keyed long Standard Endcap Manifold Endcap 16 17 16 15 19 708 20 701 10 702 8 7 703 901 902 901 703 13 13 13 14 ...

Page 49: ...ng Thrust 10 O Ring 2 153 3 487 x 375 15 Retaining Ring Internal 16 Retaining Ring External 17 Seal Lip 18 Seal Face 19 Key Shaft 20 Shim 25 Oil ISO 46 gal 701 Housing Motor 702 Kit Swash Plate 703 Kit Endcap 704 Kit Shaft 705 Kit Seal 706 Kit Speed Sensor ...

Page 50: ...e in the charge circuit Check Valve A valve whose primary function is to restrict flow in one direction Closed Loop A sealed and uninterrupted circulating path for fluid flow from the pump to the motor and back Decay Rate The ratio of pressure decay over time End Cap See Center Section Entrained Air A mechanically generated mixture of air bubbles having a tendency to separate from the liquid phase...

Page 51: ...ll of the components and allowing the air a path of escape Rated Flow The maximum flow that the power supply system is capable of maintaining at a specific operating pressure Scoring Scratches in the direction of motion of mechanical parts caused by abrasive contami nants Swash Plate A mechanical device used to control the displacement of the pump pistons in a fluid power system System Charge Chec...

Page 52: ...PRM MOTOR Service and Repair Manual ...

Page 53: ...fety 5 Tool Safety 5 Work Area Safety 5 Servicing Safety 5 Troubleshooting 6 Service and Maintenance 7 External Maintenance 7 Service and Maintenance Procedures 7 Fluids 7 Fluid Volume and Level 7 Fluid Change 7 Repair 8 How To Use This Manual 8 General Instructions 8 Required Tools 8 Torque Specifications 8 PRM Motor Removal 8 Tools 8 Disassembly 9 Assembly 17 Parts List 24 25 Glossary of Terms 2...

Page 54: ...to provide information useful in servicing and troubleshooting the Hydro Gear PRM Also included is a glossary of terms that are frequently used throughout the industry and in Hydro Gear service publications Understand ing terminology is very important It is necessary and a good shop practice that your service area be equipped with the proper tools and the mechanics be supplied the latest informati...

Page 55: ...eration The PRM motor is available in four different displacements that range from 14 to 20 cu in 229 to 327 cc per revolution The cylinder block pistons in the PRM Motor are set at a fixed displacement by a fixed swash angle that is integral to the motor housing Therefore the motor is always at maximum displacement As pressurized fluid from the pump pushes against the cylinder block pistons they ...

Page 56: ...PRM 3 EXTERNAL FEATURES PRM MOTOR Figure 1 PRM External Features ...

Page 57: ... 18CX E1XX XXXX I II IIII IIII III III I II IIII 4 348 M1 0476 MADE IN U S A Year Built Date Julian day of year Type of Product and Build Information Serial Number unique number for that model for that day Model Number Model Reference Number PRM Geometric Displacements in3 rev cc rev 14 16 18 20 229 262 294 327 Maximum Speed rpm min 1 240 240 Maximum Torque 3000 psi 206 bar lb ft daNm 600 81 Shaft...

Page 58: ...n debris from yourself or your clothing TOOL SAFETY Use the proper tools and equipment for the task Inspect each tool before use and replace any tool that may be damaged or defective WORK AREA SAFETY Keep the work area neat and orderly Be sure it is well lit that extra tools are put away trash and refuse are in the proper containers and dirt or debris have been removed from the working areas of th...

Page 59: ... loading Loose parts Air trapped in hydraulic system Internal gear failure Fill to proper level or change oil Reduce vehicle loading Repair or replace loose parts Purge hydraulic system Complete teardown reassembly UNIT HAS NO LOW POWER Engine RPM low Control linkage bent or out of adjustment Drive belt slipping or pulley damaged Oil level low or contaminated oil Excessive loading Air trapped in h...

Page 60: ...ntenance Clean ing of all parts by using a solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign material and chemicals Protect all exposed seal ing areas and open cavities from damage and foreign material Upon removal all seals O rings and gaskets should be replaced During installation lightly lubricate all seals O rings gaskets wit...

Page 61: ...iscellaneous PRM Motor Service Repair Manual Torque Wrench Impact Wrench 3 8 Drive Ratchet Scribe Paint Pen or Marker Seal Hook with a Magnet Flat Blade Screw Driver Hub Puller Adapter included in seal kit Pliers Internal Snap Ring External Snap Ring Sockets 9 16 1 5 16 Combination Wrenches 9 16 TOOLS PRM MOTOR REMOVAL It is necessary to remove the PRM motor from the vehicle before performing the ...

Page 62: ...emoval manually apply the PRM brake actuating handle 36 Fig 12 to prevent the axle from turning Use a wheel or gear puller and the hub puller adapter located in the seal kit to remove the hub from the shaft 2 Remove the woodruff key 71 from the axle shaft 34 Figure 3 MA04K045 Figure 4 MA04K026 Figure 5 MA04N046 NOTE Anytime a hub nut and or hub is removed it must be discarded and replaced with a n...

Page 63: ...he motor housing 2 5 Inspect the thrust bearing 7 and motor housing needle bearing for damage or wear 6 Remove the pistons springs and seats from the cylinder block 3 and inspect the components for damage or wear Figure 6 MA04M021 Figure 7 MA04K035 Figure 8 MA04M047 ...

Page 64: ... 12 and washer 11 from the motor shaft 13 8 Remove the cylinder block 3 from the mo tor shaft 13 Inspect the cylinder block 3 for damage or wear 9 To ease reassembly mark the port block 15 and ring gear 23 prior to disassem bly Also mark the brake actuating handle 36 Fig 12 and brake cam 31 Fig 14 Figure 9 MA04K048 Figure 10 MA04K049 Figure 11 MA04K050 ...

Page 65: ...ED 10 Remove the actuating handle retaining clip 38 and actuating handle 36 11 Remove the port block 15 and brake puck Figure 12 MA04K051 Figure 13 MA04K052 Figure 14 MA04K012 42 12 Remove the brake cam 31 from the port block 15 ...

Page 66: ...ng 71 from the port block 15 14 Remove the o ring 71 and stator spacer Figure 15 MA04K013 Figure 16 MA04K053 Figure 17 MA04N054 29 from the ring gear 23 15 Remove the brake rotor 37 stator washer 25 and motor shaft 13 Inspect all for damage or wear ...

Page 67: ...ier pins 18 and washer 26 from the ring gear 23 Inspect the gears carrier pins and washer for wear or damage Figure 18 MA04K055 Figure 19 MA04K056 Figure 20 MA04K057 17 Remove the sun gear 20 18 Remove the ring gear 23 six planetary gears 21 carrier pins 40 and o ring 71 Inspect all components for wear or damage ...

Page 68: ... internal retaining ring 39 and axle shaft 34 with ball bearing from the axle housing 1 Figure 21 MA04K058 Figure 22 MA04K028 Figure 23 MA04K027 21 Remove the external retaining ring 35 and ball bearing 30 from the axle shaft 34 This is a press fit so the bearing may be difficult to remove from the shaft Inspect the bearing and shaft for wear or damage ...

Page 69: ...RM DISASSEMBLY CONTINUED 22 Inspect the axle housing needle bearing for damage or wear Figure 24 MA04K042 Figure 25 MA04K029 23 Remove the internal retaining ring 71 and lip seal 71 from the axle housing 1 ...

Page 70: ...r bearing race only Secure the bearing with the retaining ring 35 2 Install the lip seal 71 and internal retaining ring 71 into the axle housing 3 Install axle shaft 34 with ball bearing into housing 1 and secure with retaining ring 39 Figure 26 MA04K027 Figure 27 MA04K039 Figure 28 MA04N028 SECTION 7 ASSEMBLY ...

Page 71: ...2 into the axle housing 1 Make sure the recessed face of the second ary planetary carrier 22 faces away from the axle shaft Figure 30 MA04K058 Figure 31 MA04K057 Figure 32 MA04K056 5 Install the o ring 71 ring gear 23 carrier pins 40 and six planetary gears 21 Make sure the mark that was placed on the ring gear in step 9 of the disassembly is oriented correctly 6 Install the sun gear 20 RECESSED F...

Page 72: ...three planetary gears 17 Install the washer 26 and assembly into the ring gear 23 Figure 33 MA04K055 Figure 34 MA04N054 Figure 35 MA04K053 8 Install stator washer 25 brake rotor 37 and motor shaft 13 into the ring gear 23 9 Install o ring 71 and stator spacer 29 into the ring gear 23 23 ...

Page 73: ...ure 37 MA04K012 Figure 38 MA04K052 11 Install brake cam 31 into the port block 15 12 Install puck 42 into the port block 15 then install the port block onto the motor shaft 13 Note When installing the port block assembly pull on the cam 31 Fig 37 to keep the puck 42 from falling out of the 13 ...

Page 74: ...r 23 are aligned 14 Install actuating handle 36 onto the brake Figure 39 MA04K050 Figure 40 MA04K051 Figure 41 MA04K049 cam and secure with retaining clip 38 Make sure the marks on the actuating handle and brake cam are aligned 15 Install the cylinder block 3 onto the motor shaft 13 ...

Page 75: ...retaining ring 71 Figure 42 MA04K048 Figure 43 MA04M047 Figure 44 MA04M061 17 Install the springs piston seats and pistons into the cylinder block 3 18 Place the thrust bearing 7 on the cyl inder block pistons 3 and around the mo tor shaft 13 Be sure the thick race of the thrust bearing 7 is contacting the pistons 3 13 ...

Page 76: ...t 55 Torque the top lock nut or castle nut according to the chart below Manually apply the brake actuating handle to prevent the axle shaft from turning when tightening the hex lock nut Final nut tightening can also be accomplished after the PRM and wheel have been installed on the vehicle and the vehicle is setting on the ground 1 Top Lock Nut Item 55 SILVER hub configuration Prior to serial numb...

Page 77: ...24 PRM SECTION 8 PARTS LIST Figure 48 MA04K030 ...

Page 78: ... 22 Secondary Planetary Carrier 23 48T Ring Gear 25 Stator Washer 26 Washer 28 Needle Bearing ITEMS LIST Part numbers are not provided in this manual NO DESCRIPTION 29 Stator Spacer 30 Ball Bearing 31 Brake Cam Kit 34 Shaft Axle 35 Retaining Ring External 36 Handle Actuating 37 Brake Rotor 38 Retaining Clip 39 Retaining Ring Internal 40 Carrier Pin 42 Brake Puck 55 Nut Hex Lock 56 Hub Kit 60 Brake...

Page 79: ...ressure at which replenishing fluid is forced into a fluid power system Charge Relief Valve A pressure control valve whose primary function is to limit pressure in the charge circuit Check Valve A valve whose primary function is to restrict flow in one direction Closed Loop A sealed and uninterrupted circulating path for fluid flow from the pump to the motor and back Decay Rate The ratio of pressu...

Page 80: ...quently achieved by pressurizing the fluid in the inlet line Purging The act of replacing air with fluid in a fluid power system by forcing fluid into all of the components and allowing the air a path of escape Rated Flow The maximum flow that the power supply system is capable of maintaining at a specific operating pressure Scoring Scratches in the direction of motion of mechanical parts caused b...

Page 81: ...BLN 50231 January 2018 BDP 10L PL Hydrostatic Pump Service and Repair Manual ...

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Page 93: ...Do not remove the cradle bearings Remove pump cylinder block kit block spring and washer and swashplate from housing ...

Page 94: ...ec y l i n d e r b l o c k s mu s t b e f l a t a n df r e ef r o ms c r a t c h e s I f s c r a t c h e s o r w e a r a r ef o u n do nt h er u n n i n gs u r f a c eo f t h ec y l i n d e r b l o c k o r e n dc a p r e p l a c et h ep a r t s ...

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Page 100: ...HGM 12P LSHT Wheel Motor Service and Repair Manual BLN 52197 January 2018 ...

Page 101: ...Spare parts list service manual Service 1 Hydraulic motors HGM P Page Exploded view HGM P 2 Spare parts list 3 Tightening torque 6 Dismantling 7 Assembly 11 Index ...

Page 102: ...2 Exploded view HGM P ...

Page 103: ...haft 1 32 mm shaft HPS 1 32 mm shaft 1 5 Shaft seal 25 mm 1 1 spl shaft HPS 39 28 6 4 9 mm HSN 1 1 1 25 mm 1 1 spl 42 0 28 6 5 5 mm NBR 1 1 1 1 1 28 5 mm tapered shaft 25 mm 1 1 splined 42 0 28 6 5 5 mm FPM 1 1 1 1 1 28 5 mm tapered shaft 32 mm shaft HPS 46 35 4 9 mm 1 32 mm shaft 48 0 35 0 5 5 mm NBR 1 6 O ring 25 mm 1 1 spl 47 2 3 5 mm NBR 1 1 1 1 28 5 mm tapered shaft 25 mm 48 0 2 0 mm NBR 1 32...

Page 104: ... 76 8 mm 1 OMP 40 L 94 0 mm 1 OMP 50 L 94 0 mm 1 1 1 1 OMP 50 L 76 8 mm 1 1 OMP 80 L 98 0 mm 1 1 1 1 OMP 80 L 80 7 mm 1 1 OMP 100 L 100 5 mm 1 1 1 1 OMP 100 L 83 3 mm 1 1 OMP 125 L 100 5 mm 1 1 1 1 OMP 125 L 87 1 mm 1 1 OMP 160 L 108 5 mm 1 1 1 1 OMP 160 L 91 2 mm 1 1 OMP 200 L 113 5 mm 1 1 1 1 OMP 200 L 96 4 mm 1 1 OMP 250 L 120 0 mm 1 1 1 1 OMP 250 L 102 9 mm 1 1 OMP 315 L 128 5 mm 1 1 1 1 OMP 3...

Page 105: ...P 80 l 40 mm 7 7 7 7 7 OMP 100 l 40 mm 7 7 7 7 7 OMP 125 l 45 mm 7 7 7 7 7 OMP 160 l 50 mm 7 7 7 7 7 OMP 200 l 55 mm 7 7 7 7 7 OMP 250 l 60 mm 7 7 7 7 7 OMP 315 l 70 mm 7 7 7 7 7 OMP 400 l 80 mm 7 7 7 7 7 End port motor M8 1 25 OMP 50 l 40 mm 5 5 OMP 80 l 45 mm 5 5 OMP 100 l 45 mm 5 5 OMP 160 l 55 mm 5 5 OMP 200 l 60 mm 5 5 OMP 250 l 65 mm 5 5 OMP 315 l 75 mm 5 5 OMP 400 l 85 mm 5 5 22 Name platea...

Page 106: ...motors with standard shaft seal and 1 1 1 1 1 25 mm 1 1 spl shaft 28 5 mm tapered shaft 3 1 pcs Dust seal 35 x 27 5 x 4 mm NBR 5 1 pcs Shaft seal Series 7 8 42 x 28 6 x 5 5 mm NBR 5 1 pcs Shaft seal Series 6 48 x 28 6 x 6 mm NBR 6 1 pcs O ring 47 2 x 3 5 mm NBR 6 1 pcs O ring 48 x 2 mm NBR 16 3 pcs O ring 75 9 x 1 8 mm NBR 20 7 pcs Washer 11 9 x 8 2 x 1 mm 24 1 pcs Washer 17 5 x 13 5 x 1 5 mm Spar...

Page 107: ...lated nut 11 Washer 12 Parallel key 28 Seal plugs Put the motor in a holding tool with the output shaft downward For end port version use 10 mm hexagon socket spanner 25 24 Drain plug washer If present Use a 19 mm spanner socket Dismantling ...

Page 108: ...butor plate O ring 13 Output shaft Motors with integrated spigot flange Place the motor housing on the work bench and press the shaft out of the motor housing Shaft and bearings should normally not be removed from HGM P However if necessary for inspection and cleaning remove the shaft from the back of the housing by gently tapping the axle journal with a plastic hammer The front bearing can thus r...

Page 109: ...d spigot flange Remove bearing and bearing race from the motor housing Motors with separate spigot flange Use a 2 mm screwdriver 8 Needle bearing 5 Shaft seal 3 Dust seal Motors with integrated spigot flange With mandrel and plastic hammer carefully knock out the shaft seal Motors with separate spigot flange Knock out the shaft seal dust seal with a plastic hammer Use mandrel 9 Dismantling ...

Page 110: ...h check valves Pull the check valve out with for example a ground shortened 3 5 mm screw tap Cleaning Clean all parts carefully with low aromatic kerosine Inspection and replacement Check all parts carefully and replace if necessary Lubrication Before assembly lubricate all parts with hydraulic oil and grease rubber parts with vaseline Dismantling ...

Page 111: ...plastic hammer 9 Bearing race Only HGM P with 32 mm 28 5 mm tapered shaft 5 Shaft seal Motors with integrated spigot flange Lubricate the shaft seal on the out side with hydraukic oil Fit the shaft seal correct onto mandrel and carefully press the shaft seal into position in the motor housing Motors with separate spigot flange Knock the seal into position in the spigot flange Check that the seal l...

Page 112: ...opriate mandrel 7 6 Bearing race O ring Motors with integrated spigot flange Fit bearing and bearing race onto the shaft and mount together with the shaft Motors with separate spigot flange Grease the O ring with vaseline and fit the bearing race and O ring into the spigot flange 8 Needle bearing 4 Spigot flange Turn so that the holes line up Assembly ...

Page 113: ...Output shaft Grease the journals with hydraulic oil The rear shaft end must be marked before fitted The mark must be positioned vertically above a commutation slot leading up to the front annular channel For HGM P guide the shaft into the motor housing back with the rear needle bearing fitted on the shaft Bring the shaft in line with the back of the motor by gently tapping the shaft with a plastic...

Page 114: ...o that the holes line up 14 Cardan shaft Guide the cardan shaft down into the motor housing Only OMP 25 32 40 Place the assembly tool under the upper splines of the cardan shaft In case of different splines lengths turn the cardan shaft to ensure the long splines end is fitted in the output shaft Transfer marking from output shaft to cardan shaft Assembly ...

Page 115: ...ing down towards the housing Place the gearwheel set on the cardan shaft so that the top of a tooth in the external teeth of the gearwheel are vertically above the mark on the cardan shaft Turn the gearwheel set counter clockwise until the cardan shaft and the gearwheel start to mesh 15 Turn the gearwheel rim so that the holes made for the screws line up 19 End cover Turn the end cover so that the...

Page 116: ...anner socket Tightening torque 3 6 daNm 265 536 lbf in 28 Seal plugs Threaded plug End port version Screw plastic plugs into end ports Screw in the side port plugs using 10 mm hexagon socket spanner Tightening torque 5 7 daNm 445 620 lbf in in lbs Side port version Screw in plastic plugs 12 Parallel key To be secured with tape or plastic ring 11 Washer 10 Castelated nut Assembly ...

Page 117: ...HGM E LSHT Wheel Motor Service and Repair Manual BLN 52198 January 2018 ...

Page 118: ...d Cover 5 Gearwheel Set 6 Cardan Shaft 7 Distributor Plate 8 Disc Valve 9 Shaft 9 Balance Plate 10 Bearing and Seal 11 Assembly Bearing and Seal 12 Motor Shaft 13 Balance Plate 13 Disc Valve 14 Cardan Shaft 14 Distributor Plate 15 Gearwheel Set 16 End Cover 17 Dust Cover and Woodruff Key 18 Brake and Dum 19 Exploded View 20 Parts List 21 Table Of Contents ...

Page 119: ...d the quality leader in everything we do This Service and Repair Manual is designed to provide information useful in servicing and troubleshooting the Hydro Gear HGM E Se ries motor It is necessary and a good shop practice that your service area be equipped with the proper tools and the mechanics be supplied the latest information available All repair procedures illustrated in this guide are sugge...

Page 120: ...th hydraulic oil and grease rubber parts with clean petroleum jelly Parts requiring replacement must be replaced from the appropriate parts kits identified on the Service Schematic found at the end of this manual Use only original Hydro Gear replace ment parts found in BLN 51427 CD General Description Hydro Gear HGM E wheel motors convert hy draulic energy pressure and oil flow into me chanical en...

Page 121: ...x head M8 X 110MM 300 380 lb in 35 40 Nm HGM 15E Series End Cover 25 HGM 15E Series Screw Hex head M10 X 110MM 660 720 lb in 75 80 Nm HGM 15E Series End Cover 25 HGM 18E Series Screw Hex head M8 X 130MM 310 354 lb in 35 40 Nm HGM 18E Series End Cover 25 HGM 18E Series Screw Hex head M10 X 130MM 660 720 lb in 75 80 Nm HGM 18E Series End Cover 29 Bolt 5 16 18 x 75 SHCS 180 240 in lbs 20 3 27 1 Nm Br...

Page 122: ...y must be discarded and replaced with a new assembly 3 Remove the drum hub assembly 27 4 Remove the four bolts 29 securing the brake assembly 28 to the HGM E motor See figure 2 5 Remove the brake assembly See figure 2 DRUM BRAKE Inspection 1 Inspect the studs on drum 27 for wear and or damage Replace if necessary 2 Inspect the brake assembly 28 i e the brake shoes for wear and or damage Figure 2 B...

Page 123: ...21 4 Remove the seven end cover screws 25 5 Remove the seven end cover washers 24 and discard 6 Remove the end cover 22 by sliding the end cover 22 sideways off the gear wheel set The end cover may be difficult to remove due to oil film causing it to stick END COVER Figure 3 End Cover Inspection 1 Inspect for wear or damage 2 Inspect screws 25 threads for wear or damage 3 Inspect woodruff key 10 f...

Page 124: ...g 20 and discard 3 Remove the gearwheel set 21 NOTE Placing fingers underneath gearwheel set will help keep parts from falling out 4 Remove the second O ring 20 and dis card 5 Dismantle the gear wheel set for inspection When removing the inner gearwheel notice the recess without teeth and its orientation for reassembly Inspection 1 Inspect for wear or damage 21 20 20 Cardan Shaft ...

Page 125: ...shers 24 the end cover 22 the O rings 20 and the gearwheel set 21 See Pages 5 and 6 2 Remove the cardan shaft 19 3 Take note of the difference in each end length and shape of splines Figure 5 Cardan Shaft Inspection 1 Check for wear and or damage to the indi vidual splines on the cardan shaft 19 19 ...

Page 126: ...rdan shaft 19 See pages 5 6 and 7 2 Remove the distributor plate 18 and the radial needle bearing 16 Note The radial needle bearing 16 is pressed into the distributor plate 18 and does not typically require removal NOTE The needles may fall out of the needle bearing 16 during dismantling and can be retrieved for re use Inspection 1 Inspect for wear or damage DISTRIBUTOR PLATE 18 16 ...

Page 127: ...spect for wear or damage MOTOR SHAFT Refer to Figure 8 Disassembly 1 Remove the screws 25 the washers 24 the end cover 22 the O rings 20 the gearwheel set 21 the cardan shaft 19 the distributor plate 18 the bearing race 17 the radial needle bearing 16 the dis tributor plate 18 and the disc valve 15 2 Remove the woodruff key if installed See item 10 page 5 3 With motor housing secure in a holding t...

Page 128: ...ngs 20 the gearwheel set 21 the cardan shaft 19 the distributor plate 18 the bearing race 17 the radial needle bearing 16 the disc valve 15 and the tapered shaft 11 2 Remove the balance plate 14 3 Remove the O ring 12 and discard 4 Remove the spring washer 13 5 Remove the O ring 5 and discard Inspection 1 Inspect for wear or damage 5 14 12 13 Motor Housing ...

Page 129: ...flat blade screwdriver gently lever the dust seal 3 from the motor housing and discard 5 Flip the unit back over to remove the radial needle bearing 9 A blind bearing puller must be used to remove the radial needle bearing 9 from the motor housing 6 Remove the axial needle bearing 8 and the 2 bearing races 7 7 Using a small flat blade screwdriver remove the shaft seal 6 from the bearing housing an...

Page 130: ...e hous ing and the cupped side facing toward the interior of the housing 3 Install the 2 bearing races 7 as depicted one on each side of the axial needle bear ing and the axial needle bearing 8 4 Install the radial needle bearing 9 into the housing press into place using a man drel NOTE Hold the needle bearings in place by applying a light coating of grease to the outer ring and to the needle bear...

Page 131: ...re 3 Assembly 1 Before assembly lubricate all parts with clean oil and grease rubber parts with clean petroleum jelly 2 Place the O ring 5 in the motor housing O ring recess 3 Insert O ring 12 into the recess on the bal ance plate 14 and lubricate with grease Place the spring washer 13 on the balance plate Place balance plate lightly in position so that it engages NOTE Take care not to damage O ri...

Page 132: ... with the slot in the shaft Figure 4 Disc Valve 15 11 Refer to Figure 5 Assembly 1 Before assembly lubricate all parts with clean oil 2 Note the difference in spline length on the cardan shaft 19 Fit the cardan shaft with the long spline end into the axle output shaft 11 After installation mark the top of the cardan shaft spline that lies adjacent to the long tab in the disc valve 15 See Fig 5a DI...

Page 133: ...aring 16 into the distributor plate 18 NOTE Hold the needle bearings in place by applying a light coating of grease to the outer ring and to the needle bearings 3 Place the distributor plate 18 on the motor housing so that the shaft enters the bearing 16 Press the distributor plate 18 until it stops on the housing and line up the screw holes DISTRIBUTOR PLATE 18 16 ...

Page 134: ...haft Turn the gearwheel set clockwise until the cardan shaft and internal gearwheel slips over and engages the splines 15 Turn the gear wheel rim to line up the screw holes Refer to Figure 7 Assembly 1 Before assembly lubricate all parts with clean oil and grease rubber parts with clean petroleum jelly 2 Place the O rings 20 greased in the gearwheel 21 O ring recesses If there is a recess on one e...

Page 135: ...he end cover 22 with those of the gear wheel set before inserting the screws 25 3 When tightening the screws 25 refer to the table on page 3 for the required torque values Also refer to the torque sequence illustration on the right for the proper tight ening sequence NOTE As a general rule use the low end of the torque specification on fasteners when reassembling the unit Figure 8 End Cover 22 24 ...

Page 136: ...ure 9 Assembly 1 Using a rubber or neoprene mallet and mandrel install a new dust seal 3 into the bearing housing 2 Install the woodruff key 10 onto the motor shaft 11 DUST COVER AND WOODRUFF KEY Figure 9 Dust Cover and Woodruff Key 3 11 10 ...

Page 137: ...sembly 27 onto brake as sembly 28 NOTE If the drum assembly or hub assembly is removed from the axle shaft the drum hub assembly must be discarded and replaced with a new assembly 4 Install the castellated nut 1 Torque castel lated nut as required in table on page 3 5 Install the cotter pin 30 NOTE As a general rule use the low end of the torque specification on fasteners when reassembling the uni...

Page 138: ...20 HGM E LSHT Wheel Motor HGM E SERIES EXPLODED VIEW 1 HGM E Series Motor 26 4 5 3 6 7 7 9 11 13 14 15 16 10 8 19 18 20 21 20 22 23 24 25 28 29 27 30 12 ...

Page 139: ...ial needle bearing 1 10 Woodruff key 1 11 Shaft tapered 1 12 O ring 1 13 Spring washer 1 14 Balance plate 1 15 Disc valve 1 16 Radial needle bearing 1 18 Distributor plate 1 19 Cardan shaft 1 20 O ring 2 21 Gearwheel set 1 22 End cover 1 23 Name plate 1 24 Washer 7 25 Screws 7 26 Plugs 2 27 HGB drum assembly 1 28 HGB brake assembly 1 29 Bolt 4 30 Pin cotter 1 HGM E PARTS LIST ...

Page 140: ...P Series Hydrostatic Pumps Service and Repair Manual BLN 0093 June 2018 PC PJ PK PW PY PR PG PE ...

Page 141: ... cu in PC Series the 10 cc 0 61 cu in PG Series the 12 cc 0 73 cu in PJ Series the 16 cc 0 98 cu in PR Series and the 21 cc 1 28 cu in PW Series pumps Also included is a glossary of terms that are frequently used throughout the industry and in Hydro Gear service publications Understand ing terminology is very important It is necessary and good shop practice that your service area be equipped with ...

Page 142: ...cation 12 Safety 13 Personal Safety 13 Tool Safety 13 Work Area Safety 13 Servicing Safety 13 Troubleshooting 14 15 P Series Flow Test Kit Instructions 16 17 Service and Maintenance 18 20 External Maintenance 18 Service and Maintenance Procedures 18 Fluids 18 Fluid Volume and Level 19 Fluid Change 19 Filters 19 Purging Procedures 19 Return to Neutral Setting 20 Repair 21 126 PC Series Pump 21 36 P...

Page 143: ...ssion spring located inside each piston holds the nose of the piston against a thrust bearing race The variable displacement pump features a cradle swashplate with a direct proportional displacement control Movement of the directional control shaft produces a proportional swashplate movement and a change in pump flow and or direction Reversing the direction of the angle of the swash plate reverses...

Page 144: ...2 P Series EXTERNAL FEATURES PC SERIES Figure 1 PC Pump with Standard Charge Pump ...

Page 145: ...ump EXTERNAL FEATURES PG PE SERIES SAE A PAD FLANGE STYLE CHARGE PRESSURE DIAGNOSTIC PORT INPUT SHAFT INLET A and B PORTS STANDARD CHECK VALVE OR SCR CASE DRAIN OPTION BYPASS VALVE CHARGE COVER STANDARD CHECK VALVE OR SCR TRUNNION ARM CASE DRAIN OPTION ...

Page 146: ...4 P Series EXTERNAL FEATURES PJ SERIES Figure 3 PJ Pump with Standard Charge Pump ...

Page 147: ...5 P Series Figure 4 PK Pump With Standard Charge Pump EXTERNAL FEATURES PK SERIES ...

Page 148: ...EXTERNAL FEATURES PR SERIES TRUNNION ARM INPUT SHAFT CHARGE PRESSURE DIAGNOSTIC PORT A and B PORTS INLET BYPASS VALVE CASE DRAIN CHARGE COVER CASE DRAIN SYSTEM CHECK VALVE OR SHOCK VALVE SYSTEM CHECK VALVE OR SHOCK VALVE SAE A PAD FLANGE STYLE BYPASS VALVE ...

Page 149: ...gure 5 PW PY Pump With Standard Charge Pump CHARGE COVER STANDARD CHECK VALVE OR SHOCK VALVE STANDARD CHECK VALVE OR SHOCK VALVE SAE B PAD FLANGE STYLE TRUNNION ARM INPUT SHAFT BYPASS VALVE CASE DRAIN CHARGE PRESSURE DIAGNOSTIC PORT A and B PORTS ...

Page 150: ... CHARGE DIAGNOSTIC PORT B PORT A BYPASS VALVE BLEED OPTIONS 1 NO BLEED ORIFICE 2 031 BLEED ORIFICE Orifice size No Bleed 024 Bleed 031 Bleed 044 Bleed Relief pressure psi Check ball 1740 2320 2900 Relief pressure bar Check ball 120 160 200 System Check Relief Valve Options PORT A PORT B BYPASS VALVE BLEED OPTIONS 1 NO BLEED ORIFICE 2 031 BLEED ORIFICE CHARGE DIAGNOSTIC CHARGE PUMP INLET OR OR SYST...

Page 151: ...tions Orifice size No Bleed 024 Bleed 031 Bleed 044 Bleed Relief pressure psi Check ball 1740 2320 2900 Relief pressure bar Check ball 120 160 200 System Check Relief Valve Options 650 PSI AUXILIARY DISCHARGE AUXILIARY DISCHARGE AUXILIARY RETURN AUXILIARY RETURN CHARGE PUMP INLET CHARGE DIAGNOSTIC CHG REL PORT A PORT B BYPASS VALVE BLEED OPTIONS 1 NO BLEED ORIFICE 2 031 BLEED ORI FICE BYPASS VALVE...

Page 152: ...c circuit Oil is supplied externally under pressure to an external load e g a vehicle wheel motor As the angle of the pump swashplate is increased the amount of oil being pumped will increase and cause a higher speed output of the wheel motor Reversing the angle of the swashplate will reverse the direction of the oil flow During the operation of the pump fluid is lost from the hydraulic loop throu...

Page 153: ... Continuous Max psi bar Inlet Vacuum Maximum Continuous Inches Mercury 4 Charge Pump Displacement s in3 rev cc rev 0 13 2 1 0 11 0 13 1 9 2 1 0 19 3 2 0 13 0 19 2 1 3 2 0 25 4 1 Auxiliary Pump Displacement in3 rev cc rev 0 19 3 2 0 37 6 1 Auxiliary Pump Relief Setting psi bar 650 45 950 1400 65 5 96 5 Auxiliary Pump Performance 3200 rpm 500 psi 70 SUS 13 Cst oil 180 F gpm l min 1 8 2 0 6 8 7 6 4 4...

Page 154: ...Figure 11 is located on the pump housing It identifies the model and configuration of the pump HYDRO GEAR MADE IN U S A Model Number PC AGCC MV1X XXXX 4 244 P1 0192 Year Built Date Julian day of year Type of Product and Build Information Serial Number unique number for that model for that day ...

Page 155: ... mance of your job Never allow untrained or unauthorized personnel to service or repair the equipment SECTION 2 SAFETY Wear appropriate clothing Loose or hanging cloth ing or jewelry can be hazardous Use the appropri ate safety equipment such as eye and hearing protection and safety toe and slip proof shoes Never use compressed air to clean debris from yourself or your clothing TOOL SAFETY Use the...

Page 156: ...p Troubleshooting Checklist Possible Cause Corrective Action VEHICLE DOES NOT DRIVE TRACK STRAIGHT Vehicle tires improperly inflated Refer to vehicle manufacturer suggested pressure Control linkage bent loose or out of adjustment Repair adjust or replace vehicle linkage Bypass loose Tighten pump bypass per External Maintenance step 9 page 17 Inlet Leak Check all external lines and connections to p...

Page 157: ...t leak Check all external lines and connections to pump inlet Inlet filter clogged Replace inlet filter Suspected internal damage Check pump by performing Flow Test on page 15 UNIT OPERATING HOT Debris buildup Remove debris from pump and fan Cooling fan or heat exchanger damaged Repair or replace cooling fan or heat exchanger Oil level low or contaminated oil Fill reservoir to proper level or chan...

Page 158: ...essure system lines Failure to perform this properly could result in bodily injury TESTING PROCEDURES 1 Raise the drive tires off the ground Block the remaining tires on the ground to prevent accidental vehicle movement 2 Open the restriction valve all the way 3 Make certain all external pump directional control stops are removed or backed off on the vehiclelinkage to obtain full pump directional ...

Page 159: ... values the pump would not be operating efficiently and should be repaired or replaced TEST EXAMPLE PE PG PL 300 psi 21 bar reading 7 gpm 26 l min 1st reading 1100 psi 76 bar reading 3 gpm 11 l min 2nd reading PG PL 300 psi 21 bar reading 7 gpm 26 l min 1st reading 1100 psi 76 bar reading 3 gpm 11 l min 2nd reading 4 gpm 15 l min the difference Subtract the 1st reading from the 2nd In this example...

Page 160: ...pect oil cooler if applicable for damaged fins and debris 8 Inspect the vehicle control linkage to the directional control arm on the P Series Pump Also insure the control arm is securely fastened to the trunnion arm 9 Inspect the bypass on the P Series Pump to insure it is properly engaged for operation If the bypass is not fully engaged rotated fully clockwise it will not function properly For v...

Page 161: ...e drive wheels off the ground then repeated under normal operating conditions WARNING POTENTIAL FOR SERIOUS INJURY Certain procedures require the vehicle engine to be operated and the vehicle to be raised off of the ground To prevent possible injury to the servicing techni cian and or bystanders insure the ve hicle is properly secured 1 With the bypass valve open and the engine running slowly move...

Page 162: ...s OEM s control linkage at the control arm 3 Start the engine and increase the throttle to full engine speed WARNING Do not attempt any servicing or ad justments with the engine running Use extreme caution while inspecting the drive belt assembly and all vehicle linkage Follow all safety procedures outlined in the vehicle owner s manual 4 Check for axle rotation If the axle does not rotate go to S...

Page 163: ... These seals can be replaced without major disas sembly of the unit However replacement of these seals generally requires removal of the pump from the machine Upon removal it is recommended that all seals O rings and gaskets be replaced During installation lightly lubricate all seals O rings and gaskets with clean petroleum jelly prior to assembly Also protect the inner diameter of the seals by co...

Page 164: ...Nut Hex Lock 5 16 24 UNF 4 End Cap Adapter Plate Bolts 10 Cap Screw 15 Bypass Valve 42A 42B Shock Valves Check Plugs 44 System Charge Relief Kit Aux Chg 45 Aux Relief Valve Kit 56 Diagnostic Plug 66 Filter Cover Plug 67 Filter Cover 103 Screw 5 16 x 875 106 Nut Hex Lock 5 16 24 UNF 164 Plug Metal 7 16 20 Torque 200 250 lb in 22 6 28 2 Nm 370 470 lb in 41 8 53 1 Nm 200 250 lb in 22 6 28 2 Nm 120 16...

Page 165: ...ontrol arm bracket 5 Remove the outer control arm bracket bolt 103 washer 104 and the inner return arm bracket PC SERIES PUMP REPAIR REMOVAL INSPECTION AND OR REPLACEMENT OF RETURN TO NEUTRAL ASSEMBLY Inspection 1 With the arm control linkage removed inspect the trunnion arm 37 and trunnion arm seal 49 2 Inspect bushing 101 and all other linkage parts for damage corrosion or wear Assembly 1 Instal...

Page 166: ... tighten per table 2 page 22 4 Install the fan shroud 210 onto the mounting bracket 209 Make sure that all shroud lock tabs are fully engaged in the mounting bracket slots Figure 2 Standard Control Arm Figure 3 Fan Assembly Refer to Figure 2 Disassembly 1 Remove the nut 106 washer 104 and bushing 101 2 Remove the outer control arm bracket 3 Remove bolt 103 washer 104 and the inner control arm brac...

Page 167: ...CTION AND OR REPLACEMENT OF TRUNNION ARM SEAL Figure 5 Trunnion Arm Seal Refer to Figure 5 Disassembly 1 Remove the RTN assembly or control arm 2 Remove the retainer and lip seal 49 from the housing Care must be taken to prevent damage to the housing trunnion bore trunnion arm and sealing surface Once removed the retainer and lip seal are not reusable Inspection With the lip seal 49 removed inspec...

Page 168: ...ighten to the correct torque value See Table 2 page 22 Torque Values 3 Repeat disassembly inspection and assembly for the opposite port REMOVAL INSPECTION AND OR REPLACEMENT OF SHOCK VALVES REMOVAL INSPECTION AND OR REPLACEMENT OF THE BYPASS Refer to Figure 7 Disassembly 1 Loosen the bypass valve 15 using a 7 16 inch wrench 2 Remove the bypass 15 from the end cap Inspection 1 Inspect the bypass O ...

Page 169: ...input shaft down and the end cap 2 horizontal Place the charge ball 44 in the end cap 2 charge passage so the ball mates to the end cap 2 charge ball seat Place the charge spring on top of the charge ball 4 Insert the inner gerotor over input shaft 18 5 Align the outer gerotor to fit over the inner gerotor 6 Insert the O ring 8 into the groove in the charge cover 7 Position the charge cover and O ...

Page 170: ...damage or foreign material Assembly 1 Install the check ball spring and cap as one assembly 45 into the auxiliary relief valve port Tighten to the correct torque value See page 22 2 Install the poppet spring and cap as one assembly 44 into the charge relief port Tighten to the correct torque value See page 22 3 Install the filter 54 and O ring into the filter cover assembly 67 Install the assembly...

Page 171: ... is evident when the surface is checked by dragging a fingernail across it would be cause for replacement of the end cap 2 3 Replace the housing gasket 5 with a new gasket before assembly Assembly 1 Install housing gasket 5 into housing gasket seat of housing 1 2 Lubricate the mating surface of the cylinder block 31 to end cap 2 with clean oil prior to installation 3 Install end cap 2 Before insta...

Page 172: ...stons and springs 2 Install piston seats into the end of the pistons 3 Install springs into the pistons 4 Install each piston spring and seat assembly into the cylinder block REMOVAL INSPECTION AND ASSEMBLY OF THE CYLINDER BLOCK Figure 11 PC Pump Cylinder Block Assembly NOTE To assist in cylinder block in stallation a rubber band can be placed around all of the pistons to hold them in position Aft...

Page 173: ...assembly Remove the swashplate 32 Inspection 1 Inspect the running surface of the bearing pocket of swashplate 32 for damage nicks or unusual wear patterns The running surface may show evidence of minor abrasion This is normal wear Inspect the cradle bearing side of the swashplate 32 for damage Replace if necessary 2 Inspect the cradle bearings attached to the inside of the housing 1 for normal we...

Page 174: ...ing 19 onto shaft 18 tight against the shoulder of the shaft Install retaining ring 23 onto the shaft 18 2 Install input shaft assembly 18 into the housing 1 bore Light tapping with a rubber mallet may be necessary on the input shaft 18 once the bearing is aligned with the housing 1 bore Verify that the shaft rotates smoothly 3 Install spacer 21 4 Install new lip seal 20 with the flat side of the ...

Page 175: ...tall the trunnion arm 37 into the housing 1 bore Rotate the trunnion arm to verify free movement NOTE During installation lightly lubri cate all seals O rings and gaskets with clean petroleum jelly prior to assembly Also protect the inner diameter of the seals by covering the shaft with plastic wrap Remove the plastic wrap after the seal is installed 2 Install a new seal and seal retainer 49 3 Ins...

Page 176: ...34 PC Series Figure 16 PC Pump BOXES INDICATE ITEMS INCLUDED IN Kit Number ...

Page 177: ...ice 2900 psi 200 bar 0 024 in Orifice 2900 psi 200 bar 0 031 in Orifice 2900 psi 200 bar 0 044 in Orifice 2320 psi 160 bar No Orifice 2320 psi 160 bar 0 024 in Orifice 2320 psi 160 bar 0 031 in Orifice 2320 psi 160 bar 0 044 in Orifice 1740 psi 120 bar No Orifice 1740 psi 120 bar 0 024 in Orifice 1740 psi 120 bar 0 031 in Orifice 1740 psi 120 bar 0 044 in Orifice No Description 44 Charge Relief Va...

Page 178: ...p These seals can be replaced without major disas sembly of the unit However replacement of these seals generally requires removal of the pump from the machine Upon removal it is recommended that all seals O rings and gaskets be replaced During installation lightly lubricate all seals O rings and gaskets with clean petroleum jelly prior to assembly Also protect the inner diameter of the seals by c...

Page 179: ... Screw Aux Pump and Shroud Bracket 10 Cap Screw Charge Pump Cover 15 Bypass Valve 42A 42B Shock Valves Check Plugs 44 System Charge Relief Kit Aux Chg 45 Aux Relief Valve Kit 56 Diagnostic Plug 66 Filter Cover Plug 67 Filter Cover 95 Screw Socket Head Set 103 Screw 5 16 x 875 106 Bolt 107 Nut Hex Lock 5 16 24UNF Torque 200 250 lb in 22 6 28 2 Nm 370 470 lb in 41 8 53 1 Nm 200 250 lb in 22 6 28 2 N...

Page 180: ... the outer control arm bracket 3 Remove the spring 102 bolt 106 nut 107 and washer 104 4 Remove the scissor arm 99 5 Remove the outer control arm bracket 94 bolt 103 washer 104 and the inner return arm bracket 98 Inspection 1 With the arm control linkage removed inspect the trunnion arm 37 and trunnion arm seal 49 2 Inspect scissor arm 99 and all other linkage parts for damage corrosion or wear As...

Page 181: ... 38 4 Install the fan shroud 210 onto the mounting bracket 209 Make sure that all shroud lock tabs are fully engaged in the mounting bracket slots Figure 2 PG PE Pump Standard Control Arm Figure 3 PG PE Pump Fan Assembly 209 2X 10 90 106 210 Refer to Figure 2 Disassembly 1 Remove the bolt 106 washer 104 and bushing 101 2 Remove the outer control arm bracket 3 Remove bolt 103 washer 104 and the inn...

Page 182: ...VAL INSPECTION AND OR REPLACEMENT OF TRUNNION ARM CONTROL ARM SEAL Figure 5 PG PE Pump Trunnion Arm Seal Refer to Figure 5 Disassembly 1 Remove the retainer and lip seal 49 from the housing 1 Care must be taken to prevent damage to the housing trunnion bore trunnion arm 37 and sealing surface Once removed the retainer and lip seal is not reusable Inspection 1 With the lip seal 49 removed inspect t...

Page 183: ...LACEMENT OF SYSTEM CHECK RELIEFS SCR S OR SHOCK VALVES Refer to Figure 7 Disassembly Perform disassembly inspection and assembly on SCR shock valve one side at a time Some units vary in A side to B side configuration 1 Remove the SCR 42 with a 7 8 wrench or the shock valve 42 with an 11 16 wrench 2 Remove the check relief shock valve spring and the check relief shock valve from the end cap 2 Inspe...

Page 184: ...rings and mating seats in the end cap 2 for damage or foreign materials 2 If damaged or worn replace bypass 15 Assembly 1 Lay the pump on its side so the bypass port is horizontal 2 Insert the bypass 15 into the bypass port on the end cap 2 Tighten to the proper torque value See page 38 REMOVAL INSPECTION AND OR REPLACEMENT OF THE BYPASS Figure 8 PG PE Pump Bypass 15 2 ...

Page 185: ...e cover bore for damage corrosion or wear 1 Lubricate the new shaft seal with petroleum jelly 2 Press the shaft seal into the charge cover Be careful not to damage the seal or charge cover bore 3 Position the pump with the input shaft down and the end cap 2 horizontal Place the charge ball 44 in the end cap 2 charge passage so the ball mates to the end cap 2 charge ball seat Place the charge sprin...

Page 186: ...iliary Pump 3 Inspect the filter cover assembly threads and filter for wear damage or foreign material Assembly 1 Install the check ball spring and cap as one assembly 45 into the auxiliary relief valve port Tighten to the correct torque value See page 38 2 Install the plug 56 Tighten to the correct torque value See page 38 3 Install the poppet spring and cap as one assembly into the charge relief...

Page 187: ...e valve plate 3 Inspect and replace alignment pins 3 if bent or distorted 4 Replace the housing gasket 5 with a new gasket before reassembly Assembly 1 Install housing gasket 5 into housing gasket seat of housing 1 2 Install alignment pins 3 into housing 1 3 Lubricate the valve plate prior to installation Install valve plate 31 so the stamped letters UP on the valve plate are facing up toward the ...

Page 188: ...EMOVAL INSPECTION AND ASSEMBLY OF THE CYLINDER BLOCK Figure 12 PG PE Pump Cylinder Block Assembly 1 Install piston seats into the end of the pistons 2 Install springs into the pistons 3 Install one at a time pistons springs and seats as one assembly into the cylinder block 4 With the pump housing tilted on its side install the cylinder block assembly 25 with pistons contacting the thrust bearing N...

Page 189: ...ction 1 Inspect the running surface of the bearing pocket for damage 32 nicks or unusual wear patterns The running surface may show evidence of minor abrasion This is normal wear Inspect the cradle bearing side of the swashplate 32 for damage Replace if necessary 2 Inspect the cradle bearings attached to the inside of the housing 1 for normal wear patterns placement and insure they are staked secu...

Page 190: ...t shaft seal 20 after removal Assembly Figure 15 PG PE Pump Input Shaft 1 Install input shaft assembly 18 19 23 into the housing 1 bore Light tapping with a rubber mallet may be necessary on the input shaft 18 once the bearing is aligned with the housing 1 bore Rotate the input shaft 18 to insure free movement 2 Install spacer 21 3 Install new lip seal 20 4 Remove the plastic wrap 5 Install retain...

Page 191: ...o completely reassemble the pump refer to the assembly steps on pages 39 50 Begin with the trunnion arm assembly steps listed on page 54 and complete the assembly steps in reverse order working towards the front of the manual REMOVAL AND INSPECTION OF TRUNNION ARM NOTE Upon removal it is recommended that all seals O rings and gaskets be re placed During installation lightly lubri cate all seals O ...

Page 192: ...52 PG PE Series Figure 17 PG PE Pump BOXES INDICATE ITEMS INCLUDED IN KITS Kit Number ...

Page 193: ...15mm Keyway W Aux Chg Pump Shaft Kit 9 Tooth W Std Chg Pump Shaft Kit 9 Tooth W Aux Chg Pump Shaft Kit 15mm Keyed Std Chg Thru Pump Shaft Kit 9 Tooth Thru Chg Pump Shaft Kit Tapered 19 Ball Bearing 17 X 40 X 12 20 Lip Seal 17 X 40 X 7 PTC 21 Spacer 22 Retaining Ring 25 Cylinder Block Kit 29 Block Spring 30 Block Thrust Washer 31 Valve Plate 32 Swashplate No Description 34 Ball Thrust Bearing 35 St...

Page 194: ...eals can be replaced without major disas sembly of the unit However replacement of these seals generally requires removal of the pump from the machine Upon removal it is recommended that all seals O rings and gaskets be replaced During installation lightly lubricate all seals O rings and gaskets with clean petroleum jelly prior to assembly Also protect the inner diameter of the seals by covering t...

Page 195: ...rain fitting torque System Port fitting torque Inlet fitting torque 4 End Cap Adapter Plate Bolts 10 Cap Screw 15 Bypass Valve 42A 42B Shock Valves Check Plugs 44 System Charge Relief Kit Aux Chg 45 Aux Relief Valve Kit 56 Diagnostic Plug 66 Filter Cover Plug 67 Filter Cover 103 Screw 5 16 x 875 106 Bolt 107 Nut Hex Lock 5 16 24UNF Torque 200 250 lb in 22 6 28 2 Nm 370 470 lb in 41 8 53 1 Nm 200 2...

Page 196: ...ter control arm bracket 3 Remove the spring 102 bolt 106 nut 107 and washer 104 4 Remove the scissor arm 99 5 Remove the outer control arm bracket 94 bolt 103 washer 104 and the inner return arm bracket 98 Inspection 1 With the arm control linkage removed inspect the trunnion arm 37 and trunnion arm seal 49 2 Inspect scissor arm 99 and all other linkage parts for damage corrosion or wear Assembly ...

Page 197: ... Install the fan shroud 210 onto the mounting bracket 209 Make sure that all shroud lock tabs are fully engaged in the mounting bracket slots Figure 2 PJ Pump Standard Control Arm Figure 3 PJ Pump Fan Assembly 209 10 106 90 210 Refer to Figure 2 Disassembly 1 Remove the bolt 106 nut 107 washer 104 and bushing 101 2 Remove the outer control arm bracket 3 Remove bolt 103 washer 104 and the inner con...

Page 198: ...UNNION ARM SEAL Figure 5 PJ Pump Trunnion Arm Seal Refer to Figure 5 Disassembly 1 Remove the RTN assembly or control arm 2 Remove the retainer and lip seal 49 from the housing Care must be taken to prevent damage to the housing trunnion bore trunnion arm and sealing surface Once removed the retainer and lip seal are not reusable Inspection With the lip seal 49 removed inspect the area for corrosi...

Page 199: ...ECTION AND OR REPLACEMENT OF SYSTEM CHECK RELIEFS SCR S OR SHOCK VALVES Refer to Figure 7 Disassembly Perform disassembly inspection and assembly on SCR shock valve one side at a time Some units vary in A side to B side configuration 1 Remove the SCR 42 with a 7 8 wrench or the shock valve 42 with an 11 16 wrench 2 Remove the check relief shock valve spring and the check relief shock valve from th...

Page 200: ... rings and mating seats in the end cap 2 for damage or foreign materials 2 If damaged or worn replace bypass 15 Assembly 1 Lay the pump on its side so the bypass port is horizontal 2 Insert the bypass 15 into the bypass port on the end cap 2 Tighten to the proper torque value See page 56 REMOVAL INSPECTION AND OR REPLACEMENT OF THE BYPASS Figure 8 PJ Pump Bypass 15 ...

Page 201: ...er bore for damage corrosion or wear 1 Lubricate the new shaft seal with petroleum jelly 2 Press the shaft seal into the charge cover Be careful not to damage the seal or charge cover bore 3 Position the pump with the input shaft down and the end cap 2 horizontal Place the charge ball 44 in the end cap 2 charge passage so the ball mates to the end cap 2 charge ball seat Place the charge spring on ...

Page 202: ...MP IF EQUIPPED 3 Inspect the filter cover assembly threads and filter for wear damage or foreign material Assembly 1 Install the check ball spring and cap as one assembly 45 into the auxiliary relief valve port Tighten to the correct torque value See page 56 2 Install the poppet spring and cap 44 as one assembly into the charge relief port Tighten to the correct torque value See page 56 3 Install ...

Page 203: ... transfer that is evident when the surface is checked by dragging a fingernail across it would be cause for replacement of the end cap 2 3 Replace the housing gasket 5 with a new gasket before assembly Assembly 1 Install housing gasket 5 into gasket seat of housing 1 2 Lubricate the cylinder block 25 to end cap 2 mating surface with clean oil prior to installation 3 Install end cap 2 Before instal...

Page 204: ...oil to the pistons and springs REMOVAL INSPECTION AND ASSEMBLY OF THE CYLINDER BLOCK Figure 12 PJ Pump Cylinder Block 2 Install piston seats into the end of the pistons 3 Install springs into the pistons 4 Install each piston spring and seat assembly into the cylinder block 5 With the pump housing tilted on its side install the cylinder block assembly 25 with pistons contacting the thrust bearing ...

Page 205: ...14 Disassembly 1 Remove the swashplate 32 Inspection 1 Inspect the running surface of the bearing pocket of swashplate 32 for damage nicks or unusual wear patterns The running surface may show evidence of minor abrasion This is normal wear Inspect the cradle bearing side of the swashplate 32 for damage Replace if necessary 2 Inspect the cradle bearings attached to the inside of the housing 1 for n...

Page 206: ...gs and gaskets should be replaced Assembly Figure 15 PJ Pump Input Shaft 1 If removed press bearing 19 onto shaft 18 tight against the shoulder of the shaft Install retaining ring onto the shaft 18 2 Install input shaft assembly 18 into the housing 1 bore Light tapping with a rubber mallet may be necessary on the input shaft 18 once the bearing is aligned with the housing 1 bore Verify that the sh...

Page 207: ...rm if necessary 2 Check for excessive play between trunnion arm 37 and housing 1 Replace housing if necessary Assembly 1 Install the trunnion arm 37 into the housing 1 bore Rotate the trunnion arm to verify free movement 2 Install a new seal and seal retainer 49 3 Install slot guide 38 4 To completely assembly the pump refer to the assembly steps on pages 57 68 Begin with the trunnion arm assembly...

Page 208: ...70 PJ Series Figure 17 PJ Pump BOXES INDICATE ITEMS INCLUDED IN Kit Number ...

Page 209: ...Shaft Kit Blind 15mm Keyway W Aux Chg Pump Shaft Kit 9 Tooth W Std Chg Pump Shaft Kit 9 Tooth W Aux Chg Pump Shaft Kit 15mm Keyed Std Chg Thru Pump Shaft Kit 9 Tooth Thru Chg Pump Shaft Kit Tapered 19 Ball Bearing 17 X 40 X 12 20 Lip Seal 17 X 40 X 7 PTC 21 Spacer 22 Retaining Ring 25 Cylinder Block Kit 29 Block Spring No Description 34 Ball Thrust Bearing 35 Stud Torque 37 Trunnion Arm Trunnion R...

Page 210: ...eals can be replaced without major disas sembly of the unit However replacement of these seals generally requires removal of the pump from the machine Upon removal it is recommended that all seals O rings and gaskets be replaced During installation lightly lubricate all seals O rings and gaskets with clean petroleum jelly prior to assembly Also protect the inner diameter of the seals by covering t...

Page 211: ...m and or Description Case Drain fitting torque System Port fitting torque Inlet fitting torque 4 End Cap Adapter Plate Bolts 10 Cap Screw 15 Bypass Valve 42A 42B Shock Valves Check Plugs 44 System Charge Relief Kit Aux Chg 45 Aux Relief Valve Kit 56 Diagnostic Plug 66 Filter Cover Plug 67 Filter Cover 103 Screw 5 16 x 875 106 Bolt Torque 200 250 lb in 22 6 28 2 Nm 370 470 lb in 41 8 53 1 Nm 200 25...

Page 212: ...arm 99 5 Remove the outer control arm bracket 94 bolt 103 washer 104 and the inner return arm bracket 98 PK SERIES PUMP REPAIR REMOVAL INSPECTION AND OR REPLACEMENT OF RETURN TO NEUTRAL ASSEMBLY Inspection 1 With the arm control linkage removed inspect the trunnion arm 37 and trunnion arm seal 49 2 Inspect scissor arm 99 and all other linkage parts for damage corrosion or wear Assembly 1 Install t...

Page 213: ...106 and tighten per table 2 page 74 4 Install the fan shroud 210 onto the mounting bracket 209 Make sure that all shroud lock tabs are fully engaged in the mounting bracket slots Figure 2 PK Pump Standard Control Arm Figure 3 PK Pump Fan Assembly Refer to Figure 2 Disassembly 1 Remove the bolt 106 washer 104 and bushing 101 2 Remove the outer control arm bracket 3 Remove bolt 103 washer 104 and th...

Page 214: ...UNNION ARM SEAL Figure 5 PK Pump Trunnion Arm Seal Refer to Figure 5 Disassembly 1 Remove the RTN assembly or control arm 2 Remove the retainer and lip seal 49 from the housing Care must be taken to prevent damage to the housing trunnion bore trunnion arm and sealing surface Once removed the retainer and lip seal are not reusable Inspection With the lip seal 49 removed inspect the area for corrosi...

Page 215: ...ECTION AND OR REPLACEMENT OF SYSTEM CHECK RELIEFS SCR S OR SHOCK VALVES Refer to Figure 7 Disassembly Perform disassembly inspection and assembly on SCR shock valve one side at a time Some units vary in A side to B side configuration 1 Remove the SCR 42 with a 7 8 wrench or the shock valve 42 with an 11 16 wrench 2 Remove the check relief shock valve spring and the check relief shock valve from th...

Page 216: ... rings and mating seats in the end cap 2 for damage or foreign materials 2 If damaged or worn replace bypass 15 Assembly 1 Lay the pump on its side so the bypass port is horizontal 2 Insert the bypass 15 into the bypass port on the end cap 2 Tighten to the proper torque value See page 74 REMOVAL INSPECTION AND OR REPLACEMENT OF THE BYPASS Figure 8 PK Pump Bypass 15 ...

Page 217: ...er bore for damage corrosion or wear 1 Lubricate the new shaft seal with petroleum jelly 2 Press the shaft seal into the charge cover Be careful not to damage the seal or charge cover bore 3 Position the pump with the input shaft down and the end cap 2 horizontal Place the charge ball 44 in the end cap 2 charge passage so the ball mates to the end cap 2 charge ball seat Place the charge spring on ...

Page 218: ...MP IF EQUIPPED 3 Inspect the filter cover assembly threads and filter for wear damage or foreign material Assembly 1 Install the check ball spring and cap as one assembly 45 into the auxiliary relief valve port Tighten to the correct torque value See page 74 2 Install the poppet spring and cap 44 as one assembly into the charge relief port Tighten to the correct torque value See page 74 3 Install ...

Page 219: ... transfer that is evident when the surface is checked by dragging a fingernail across it would be cause for replacement of the end cap 2 3 Replace the housing gasket 5 with a new gasket before assembly Assembly 1 Install housing gasket 5 into gasket seat of housing 1 2 Lubricate the cylinder block 25 to end cap 2 mating surface with clean oil prior to installation 3 Install end cap 2 Before instal...

Page 220: ...oil to the pistons and springs REMOVAL INSPECTION AND ASSEMBLY OF THE CYLINDER BLOCK Figure 12 PK Pump Cylinder Block 2 Install piston seats into the end of the pistons 3 Install springs into the pistons 4 Install each piston spring and seat assembly into the cylinder block 5 With the pump housing tilted on its side install the cylinder block assembly 25 with pistons contacting the thrust bearing ...

Page 221: ...14 Disassembly 1 Remove the swashplate 32 Inspection 1 Inspect the running surface of the bearing pocket of swashplate 32 for damage nicks or unusual wear patterns The running surface may show evidence of minor abrasion This is normal wear Inspect the cradle bearing side of the swashplate 32 for damage Replace if necessary 2 Inspect the cradle bearings attached to the inside of the housing 1 for n...

Page 222: ...gs and gaskets should be replaced Assembly Figure 15 PK Pump Input Shaft 1 If removed press bearing 19 onto shaft 18 tight against the shoulder of the shaft Install retaining ring onto the shaft 18 2 Install input shaft assembly 18 into the housing 1 bore Light tapping with a rubber mallet may be necessary on the input shaft 18 once the bearing is aligned with the housing 1 bore Verify that the sh...

Page 223: ...rm if necessary 2 Check for excessive play between trunnion arm 37 and housing 1 Replace housing if necessary Assembly 1 Install the trunnion arm 37 into the housing 1 bore Rotate the trunnion arm to verify free movement 2 Install a new seal and seal retainer 49 3 Install slot guide 38 4 To completely assembly the pump refer to the assembly steps on pages 75 86 Begin with the trunnion arm assembly...

Page 224: ...88 PK Series Figure 17 PK Pump BOXES INDICATE ITEMS INCLUDED IN Kit Number ...

Page 225: ...y W Std Chg Pump Shaft Kit Blind 15mm Keyway W Aux Chg Pump Shaft Kit 9 Tooth W Std Chg Pump Shaft Kit 9 Tooth W Aux Chg Pump Shaft Kit 15mm Keyed Std Chg Thru Pump Shaft Kit 9 Tooth Thru Chg Pump Shaft Kit Tapered 19 Ball Bearing 17 X 40 X 12 20 Lip Seal 17 X 40 X 7 PTC 21 Spacer 22 Retaining Ring 25 Cylinder Block Kit 29 Block Spring No Description 34 Ball Thrust Bearing 35 Stud Torque 37 Trunni...

Page 226: ... can be replaced without major disas sembly of the unit However replacement of these seals generally requires removal of the pump from the machine Upon removal it is recommended that all seals O rings and gaskets be replaced During installation lightly lubricate all seals O rings and gaskets with clean petroleum jelly prior to assembly Also protect the inner diameter of the seals by covering the s...

Page 227: ...ting torque Inlet fitting torque Fan Nut Hex Lock 5 16 24 UNF 42A 42B Shock Valves Check Plugs 45 Aux Relief Valve Kit 49 Aux Bypass Check Kit 50 Bypass Valve 56 Screw 58 Hex Screw 67 Filter Cover 102 Cap Screw Socket Head M8 x 1 25 x 25 107 Screw 5 16 24 x 75 151 Diagnostic Plug 156 Filter Cover Plug Torque 200 250 lb in 22 6 28 2 Nm 370 470 lb in 41 8 53 1 Nm 200 250 lb in 22 6 28 2 Nm 160 220 l...

Page 228: ...Remove the outer control arm bracket 101 bolt 107 washer 99 and inner control arm bracket 105 PR SERIES PUMP REPAIR REMOVAL INSPECTION AND OR REPLACEMENT OF RETURN TO NEUTRAL ASSEMBLY Inspection 1 With the arm control linkage removed inspect the trunnion arm 13 and trunnion arm seal 12 2 Inspect bushing 106 and all other linkage parts for damage corrosion or wear Assembly 1 Install the inner retur...

Page 229: ...ble 2 page 92 4 Install the fan shroud 210 onto the mounting bracket 209 Make sure that all shroud lock tabs are fully engaged in the mounting bracket slots Figure 2 PR Pump Standard Control Arm Figure 3 PR Pump Fan Assembly Refer to Figure 2 Disassembly 1 Remove the bolt 102 washer 99 and bushing 106 2 Remove the outer control arm bracket 101 3 Remove bolt 107 washer 99 and the inner control arm ...

Page 230: ...PLACEMENT OF TRUNNION ARM CONTROL ARM SEAL Figure 5 PR Pump Trunnion Arm Seal Refer to Figure 5 Disassembly 1 Remove the retainer and lip seal 12 from the housing 15 Care must be taken to prevent damage to the housing trunnion bore trunnion arm 13 and sealing surface Once removed the retainer and lip seal is not reusable Inspection 1 With the lip seal 12 removed inspect the area for corrosion and ...

Page 231: ...ACEMENT OF SYSTEM CHECK RELIEFS SCR S OR SHOCK VALVES Refer to Figure 7 Disassembly Perform disassembly inspection and assembly on SCR shock valve one side at a time Some units vary in A side to B side configuration 1 Remove the SCR 42 with a 7 8 wrench or the shock valve 42 with an 11 16 wrench 2 Remove the check relief shock valve spring and the check relief shock valve from the end cap 25 Inspe...

Page 232: ...ings and mating seats in the end cap 25 for damage or foreign materials 2 If damaged or worn replace bypass 50 Assembly 1 Lay the pump on its side so the bypass port is horizontal 2 Insert the bypass 50 into the bypass port on the end cap 25 Tighten to the proper torque value See page 92 REMOVAL INSPECTION AND OR REPLACEMENT OF THE BYPASS Figure 8 PR Pump Bypass 25 50 ...

Page 233: ...ge corrosion or wear 1 Lubricate the new shaft seal with petroleum jelly 2 Press the shaft seal into the charge cover Be careful not to damage the seal or charge cover bore 3 Position the pump with the input shaft down and the end cap 25 horizontal Place the charge ball 44 in the end cap 25 charge passage so the ball mates to the end cap 25 charge ball seat Place the charge spring on top of the ch...

Page 234: ...and mounting seats 3 Inspect the filter cover assembly threads and filter for wear damage or foreign material Assembly 1 Install the check ball spring and cap as one assembly 45 into the auxiliary relief valve port Tighten to the correct torque value See page 92 2 Install the poppet spring and cap as one assembly 49 into the charge relief port Tighten to the correct torque value See page 92 3 Inst...

Page 235: ...se for replacement of the valve plate 3 Inspect and replace alignment pins 26 if bent or distorted 4 Replace the housing O ring 28 with a new O ring before reassembly Assembly 1 Install O ring 28 into the O ring seat of housing 15 2 Install alignment pins 26 into housing 15 3 Lubricate the valve plate prior to installation Install valve plate 29 so the bronze side of the valve plate is facing down...

Page 236: ...EMBLY OF THE CYLINDER BLOCK Figure 12 PR Pump Cylinder Block Assembly 1 Install piston seats into the end of the pistons 2 Install springs into the pistons 3 Install one at a time pistons springs and seats as one assembly into the cylinder block 4 With the pump housing tilted on its side install the cylinder block assembly 38 with pistons contacting the thrust bearing NOTE To check that piston pla...

Page 237: ...f minor abrasion This is normal wear Inspect the cradle bearing side of the swashplate 31 for damage Replace if necessary 2 Inspect the cradle bearings attached to the inside of the housing 15 for normal wear patterns placement and insure they are staked securely in place If damaged replace housing 15 REMOVAL INSPECTION OF SWASHPLATE INSPECTION OF CRADLE BEARINGS NOTE The cradle bearings will have...

Page 238: ... housing 15 bore Light tapping with a rubber mallet may be necessary on the input shaft 1 once the bearing is aligned with the housing bore 15 Rotate the input shaft 1 to insure free movement 2 Install spacer 4 3 Install new lip seal 6 4 Install retaining ring 3 NOTE If trunnion arm is to be removed delay reassembly of input shaft assem bly 4 Inspect and replace the retaining ring 3 if it is bent ...

Page 239: ...o completely reassemble the pump refer to the assembly steps on pages 93 104 Begin with the trunnion arm assembly steps listed on page 90 and complete the assembly steps in reverse order working towards the front of the manual REMOVAL AND INSPECTION OF TRUNNION ARM NOTE Upon removal it is recommended that all seals O rings and gaskets be re placed During installation lightly lubri cate all seals O...

Page 240: ...106 PR Series Figure 17 PR Pump BOXES INDICATE ITEMS INCLUDED IN KITS Kit Number ...

Page 241: ...otor Hsg Assembly 0 19 cu in rev 42 Check Valve Kit blank orifice Check Valve Kit 0 24 orifice Check Valve Kit 031 orifice Check Valve Kit 044 orifice Shock Valve Kit blank orifice Shock Valve Kit 024 orifice No Description No Description Shock Valve Kit 031 orifice Shock Valve Kit 044 orifice 44 Charge Relief Kit 1 4 plastic ball spring Charge Relief Kit 1 4 plastic ball spring Charge Relief Kit ...

Page 242: ...t major disas sembly of the unit However replacement of these seals generally requires removal of the pump from the machine Upon removal it is recommended that all seals O rings and gaskets be replaced During installation lightly lubricate all seals O rings and gaskets with clean petroleum jelly prior to assembly Also protect the inner diameter of the seals by covering the shaft with a cellophane ...

Page 243: ...44 Charge Relief Kit 45 Aux Relief Valve Kit 49 Aux Bypass Check Kit 50 Bypass Valve 56 Screw 58 Housing Bolt 66 Steel Plug 67 Filter Cover 70 Relief Valve 79 Pan Head Screw 158 Plug 9 16 166 Plug 167 Plug Screw Socket Hd Control Arm 5 16 24 x 75 Screw Socket Hd RTN M8 x 1 25 x 25 Torque 370 470 lb in 41 8 53 1 Nm 370 470 lb in 41 8 53 1 Nm 370 470 lb in 41 8 53 1 Nm 180 220 lb in 20 3 24 9 Nm 180...

Page 244: ...bracket 114 5 Remove the outer control arm bracket 111 bolt 117 washer 109 and inner control arm bracket 115 PW PY SERIES PUMP REPAIR REMOVAL INSPECTION AND OR REPLACEMENT OF RETURN TO NEUTRAL ASSEMBLY Inspection 1 With the arm control linkage removed inspect the trunnion arm and trunnion arm seal 2 Inspect bushing 116 and all other linkage parts for damage corrosion or wear Assembly 1 Install the...

Page 245: ...table 2 page 110 4 Install the fan shroud 210 onto the mounting bracket 209 Make sure that all shroud lock tabs are fully engaged in the mounting bracket slots Figure 2 PW PY Pump Standard Control Arm Figure 3 PW PY Pump Fan Assembly Refer to Figure 2 Disassembly 1 Remove the bolt 112 washer 109 and bushing 116 2 Remove the outer control arm bracket 111 3 Remove bolt 117 washer 109 and the inner c...

Page 246: ... Shaft Seal REMOVAL INSPECTION AND OR REPLACEMENT OF TRUNNION ARM CONTROL ARM SEAL Figure 5 PW PY Pump Trunnion Arm Seal Refer to Figure 5 Disassembly 1 Remove the retainer and lip seal 12 Care must be taken to prevent damage to the housing trunnion bore trunnion arm 13 and sealing surface Once removed the retainer and lip seal 12 is not reusable Inspection 1 With the lip seal 12 removed inspect t...

Page 247: ...R REPLACEMENT OF SYSTEM CHECK RELIEFS SCR S OR SHOCK VALVES Refer to Figure 7 Disassembly Perform disassembly inspection and assembly on SCR shock valve one side at a time Some units vary in A side to B side configuration 1 Remove the SCR 42 with a 7 8 wrench or the shock valve 42 with an 11 16 wrench 2 Remove the check relief shock valve spring and the check relief shock valve from the end cap 25...

Page 248: ...ings and mating seats in the end cap 25 for damage or foreign materials 2 If damaged or worn replace bypass 50 Assembly 1 Lay the pump on its side so the bypass port is horizontal 2 Insert the bypass 50 into the bypass port on the end cap 25 Tighten reference Table 2 page 110 torque values REMOVAL INSPECTION AND OR REPLACEMENT OF THE BYPASS Figure 8 PW PY Pump Bypass 50 25 ...

Page 249: ... cover Be careful not to damage the seal or charge cover bore 3 Position the pump with the input shaft down and the end cap 25 horizontal Place the charge ball 44 in the end cap 25 charge passage so the ball mates to the end cap 25 charge ball seat Place the charge spring 44 on top of the charge ball 4 Insert the inner gerotor over input shaft 5 Align the outer gerotor to fit over the inner geroto...

Page 250: ...all O rings gasket and mounting seats 3 Inspect the filter cover assembly threads and filter for wear damage or foreign material Assembly 1 Install the check ball spring and cap as one assembly 45 into the auxiliary relief valve port Tighten to the correct torque value See page 110 2 Install the poppet spring and cap as one assembly 44 into the charge relief port Tighten to the correct torque valu...

Page 251: ...ce on portblock 40 Grooving in the portblock made evident when the surface is checked by dragging a fingernail across the surface would be cause for replacement 5 Inspect gerotor 41 O ring 39 and end cap 25 Assembly 1 After the endcap 25 has been installed on the pump housing 15 Position the pump with the input shaft down and the end cap 25 horizontal Place the charge ball 44 in the end cap 25 cha...

Page 252: ...ce alignment pins 26 if bent or distorted 3 Replace the housing O ring 28 with a new O ring before reassembly Assembly 1 Install housing O ring 28 into O ring seat of housing 15 2 Install alignment pins 26 into housing 15 3 Lubricate the valve plate prior to installation Install valve plate 29 with the bronze side down contacting the cylinder block NOTE This step is only applicable on PW series pu...

Page 253: ...MBLY OF THE CYLINDER BLOCK Figure 13 PW PY Pump Cylinder Block Assembly 1 Install piston seats into the end of the pistons 2 Install springs into the pistons 3 Install one at a time pistons springs and seats as one assembly into the cylinder block 4 With the pump housing tilted on its side install the cylinder block assembly 38 with pistons contacting the thrust bearing NOTE To check that piston p...

Page 254: ...mage 31 nicks or unusual wear patterns The running surface may show evidence of minor abrasion This is normal wear Inspect the cradle bearing side of the swashplate 31 for damage Replace if necessary 2 Inspect the cradle bearings attached to the inside of the housing 15 for normal wear patterns placement and insure they are staked in place If damaged replace housing 15 REMOVAL INSPECTION AND ASSEM...

Page 255: ... 15 bore Light tapping with a rubber mallet may be necessary on the input shaft 1 once the bearing is aligned with the housing bore 15 Rotate the input shaft 1 to insure free movement 2 Install spacer 4 3 Install new lip seal 6 Remove the plastic wrap 4 Install retaining ring 3 NOTE If trunnion arm is to be removed delay reassembly of input shaft assem bly 4 Inspect and replace the retaining ring ...

Page 256: ...ly reassemble the pump refer to the assembly steps on pages 111 122 Begin with the trunnion arm assembly steps listed on page 122 and complete the assembly steps in reverse order working towards the front of the manual REMOVAL AND INSPECTION OF TRUNNION ARM NOTE Upon removal it is recommended that all seals O rings and gaskets be re placed During installation lightly lubri cate all seals O rings a...

Page 257: ...124 PW PY Series Figure 17 PW PY Pump 85 Overhaul Seal Kit BOXES INDICATE ITEMS INCLUDED IN KITS Kit Number ...

Page 258: ... spline clear zinc cover Charge Pump Kit CW splined Aux 40 70 psi Charge Pump Kit CW splined Aux 135 165 psi Charge Pump Kit CCW splined Aux 40 70 psi Charge Pump Kit AL Aux 7 16 SAE port 40 70 psi No Description No Description Charge Pump Kit AL Aux 7 16 SAE port 75 105 psi Charge Pump Kit 6cc Aux 41 Gerotor Assembly 0 19 in3 rev Aux Gerotor HSG Assembly 0 19 in3 rev Gerotor Assembly 0 13 in3 rev...

Page 259: ...sure The pressure at which replenishing fluid is forced into a fluid power system Charge Relief Valve A pressure control valve whose primary function is to limit pressure in the charge circuit Check Valve A valve whose primary function is to restrict flow in one direction Closed Loop A sealed and uninterrupted circulating path for fluid flow from the pump to the motor and back Decay Rate The ratio...

Page 260: ...f replacing air with fluid in a fluid power system Rated Flow The maximum flow that the pump is capable of supplying Scoring Scratches in the direction of motion of mechanical parts caused by abrasive contami nants Shock Valve A relief valve in the closed loop of the hydrostatic circuit that provides makeup oil as well as protecting the circuit from high pressure shocks or spikes Swashplate A mech...

Page 261: ...HGM C LSHT Wheel Motor Service and Repair Manual BLN 52690 January 2018 ...

Page 262: ...rake Assemblies 4 Notes 19 Disassembly Service Position 5 End Cover 6 Gearwheel Set 7 Cardan Shaft 7 Distributor Plate 8 Output Shaft 8 Needle Bearing 9 Shaft Seal 9 Check Valves 10 Assembly Ball Bearing 11 Check Valves 12 Needle Bearing 12 Output Shaft 13 Retaining Ring 14 Cardan Shaft 14 Distributor Plate 15 Gearwheel Set 15 End Cover 16 Table of Contents ...

Page 263: ... quality leader in everything we do This Service and Repair Manual is designed to provide information useful in servicing and troubleshooting the Hydro Gear HGM C mo tor It is necessary and a good shop practice that your service area be equipped with the proper tools and the mechanics be supplied the latest information available All repair procedures illustrated in this guide are suggested but pre...

Page 264: ...eplacement must be replaced from the appropriate kits identified in the Items Listing found at the end of this manual Use only original Hydro Gear replacement parts found in BLN 51427 CD General Description Hydro Gear HGM C wheel motors convert hydraulic energy pressure and oil flow into mechanical energy torque and speed Hydro Gear wheel motors are of a fixed displacement LSHT design For a given ...

Page 265: ...ress REQUIRED TORQUE VALUES Item Description Torque Operation 1 Castellated nut 160 210 ft lbs 217 284 Nm Brake Drum Assembly 22 Screw Hex head 1 4 20 x 1 25 354 in lbs 40 Nm End Cover 29 Bolt 5 16 18 x 75 SHCS 180 240 in lbs 20 3 27 1 Nm Brake Assembly TOOLS As a general rule use the low end of the torque specification on fasteners when reassembling the unit TORQUES ...

Page 266: ... bolts 29 securing the brake assembly to the HGM motor See figure 2 5 Remove the brake assembly See figure 2 Inspection 1 Inspect the studs on drum for wear and or damage Replace if necessary 2 Inspect the brake assembly i e the brake shoes for wear and or damage Assembly 1 Reassemble all parts in the reverse order of disassembly 2 When tightening the fasteners refer to the table on page 3 for the...

Page 267: ...mark See figure 3 2 Remove the castellated nut 1 See figure 4 3 Remove the woodruff key 6 and the plastic plugs or fittings 8 if installed See figure 4 Drain oil from the motor 4 Remove the retaining ring 2 See figure 5 5 Place the HGM C motor into a holding tool See figure 6 SERVICE PREPARATION Figure 5 Retaining Ring Figure 4 Nut Woodruff Key and Plugs Figure 6 Service position Inspection 1 Insp...

Page 268: ...ee page 5 2 Using a 13mm wrench remove the seven screws 22 See figure 7 3 Remove the seven washers 23 and dis card 4 Remove the end cover 19 by sliding the end cover sideways off the gearwheel set See figure 8 Inspection 1 Inspect for wear or damage 2 Inspect screws 22 threads for wear or damage END COVER Figure 7 Screws Figure 8 End Cover ...

Page 269: ... will help keep parts from falling out 3 Remove second O ring 16 under gear wheel set and discard 4 Dismantle the gearwheel set for inspection if contamination or damage is suspected Inspection 1 Inspect for wear or damage CARDAN SHAFT Disassembly 1 Remove castellated nut 1 woodruff key 6 plastic plugs 8 retaining ring 2 seven screws 22 seven washers 23 end cover 19 and the gearwheel set 17 with O...

Page 270: ... Remove and discard the O ring 13 See figure 11 Inspection 1 Inspect for wear or damage DISTRIBUTOR PLATE Figure 11 Distributor Plate OUTPUT SHAFT Disassembly 1 Remove castellated nut 1 woodruff key 6 plastic plugs 8 retaining ring 2 seven screws 22 seven washers 23 end cover 19 the gearwheel set 17 with O rings 16 18 cardan shaft 15 distributor plate 14 and O ring 13 See pages 4 8 2 Place the mot...

Page 271: ... with a pressing tool See figure 14 Note The needles may fall out of the needle bearing 12 during dismantling and can be retrieved for re use Inspection 1 Inspect for wear or damage Disassembly 1 Remove castellated nut 1 woodruff key 6 plastic plugs 8 retaining ring 2 seven screws 22 seven washers 23 end cover 19 gearwheel set 17 with O rings 16 18 cardan shaft 15 distributor plate 14 O ring 13 an...

Page 272: ...16 18 cardan shaft 15 distributor plate 14 O ring 13 output shaft 7 needle bearing 12 And from the output shaft remove ball bearing 3 washer 4 and output shaft seal 5 See pages 4 9 2 Remove the check valves 11 with a ground 3 5mm screw tap See figure 15 The check valves are pressed in and can be removed by pulling on the tap Inspection 1 Inspect for wear or damage Figure 15 Check Valves Check Valv...

Page 273: ...ydraulic oil and grease rubber parts with clean petroleum jelly 1 Place the bullet on the output shaft 7 and mount the output shaft seal 5 See figure 1 2 Remove the bullet and mount the washer 4 See figure 2 3 Place the ball bearing 3 onto output shaft 7 and press into position See figure 3 Figure 1 Bullet Output Shaft Seal BALL BEARING Figure 3 Ball Bearing Press Tool Figure 2 Washer ...

Page 274: ...figure 4 3 Install the two check valves 11 into their bores See figure 5 4 Seat the check valves 11 by lighty tapping with a rubber hammer See figure 5 CHECK VALVES Figure 4 Service Position Figure 5 Check Valve NEEDLE BEARING Assembly 1 Mount seal 5 washer 4 and ball bearing 3 onto output shaft 7 See page 11 2 Install the check valves 11 3 Place the needle bearing 12 into mo tor housing 9 then pr...

Page 275: ...rd See figure 7 4 The rear of the output shaft 7 must be marked before fitted into motor housing 9 The mark must be positioned vertically above a commutation slot leading up to the front annular channel See figure 8 5 Grease the journals with hydraulic oil 6 Position output shaft 7 over motor hous ing 9 and carefully lower into the motor housing 9 Press the output shaft with ball bearing washer an...

Page 276: ...re 12 Cardan Shaft Marks Motor housing not shown Figure 11 O ring Cardan Shaft RETAINING RING Assembly 1 Mount seal 5 washer 4 and ball bearing 3 onto output shaft 7 See page11 2 Install check valves 11 needle bearing 12 output shaft assembly and retaining ring 2 See pages 12 14 3 Turn motor housing 9 so that its rear end is upwards and install a new O ring 13 See figure 11 4 Guide the cardan shaf...

Page 277: ...12 output shaft assembly retaining ring 2 and O ring 13 See pages 12 14 3 Turn the distributor plate 14 so that the slots are against the motor housing 9 and indentation in the distributor plate is pointing to port surface See figure 13 Assembly 1 Mount seal 5 washer 4 and ball bearing 3 onto output shaft 7 See page 11 2 Install check valves 11 needle bearing 12 output shaft assembly retaining rin...

Page 278: ...eel set 17 with non through splines place the gearwheel set 17 with the recess in the spline hole facing down towards the motor housing 9 5 Fit the gearwheel set 17 on the cardan shaft 15 so that the top of the tooth in the external teeth of the gearwheel is vertically over the mark on the cardan shaft 6 Turn the gearwheel set 17 counter clock wise until the cardan shaft 15 and the internal gearwh...

Page 279: ...D COVER continued Figure 18 Torque Sequence Assembly 3 Install the woodruff key 6 nut 1 and plastic plugs or fittings 8 See figure 19 NOTE If the drum assembly or hub assembly is removed from the axle shaft the drum hub assembly must be discarded and replaced with a new assembly 4 Refer to page 4 for brake hub installation instructions Assembly ...

Page 280: ...g 3 Ball Bearing 4 Washer 5 Shaft Seal 6 Woodruff Key 7 Output Shaft 8 Plastic Plugs 9 Housing 11 Check Valve 12 Needle Bearing 13 O ring 14 Distributor plate 15 Cardan Shaft 16 O ring 17 Gearwheel set 18 O ring 19 End Cover 20 Label 22 Screw 23 Washer 200 Seal Kit Exploded View Check out the collection of outdoor tools equipment we offer ...

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