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GeneralPurposeMotors2GeneralPurposeMotorsSSeriesGerolerMotorsToolsrequiredfordisassemblyandreassembly.lTorquewrench(34Nm[300Ib-in]capacity)l300-400mm[12-16inch]breakerbarl5/16-12pointsocketno.5422(HeavyDuty-56Nm[500Ib-in]capacity)l5/1612pointsocketno.5422(HeavyDuty-56Nm[500Ib-in]capacity)lSmallscrewdriver(150-200x6mm[6-8x.25inch]flatblade),seepage6fortoolinginformation.l3/16inch[5mm]hexkeylShaftpressuresealinstallationtoolfor-008motorP/N600470lShaftpressuresealinstallationtoolfor-009and-010motorsP/N600523lSealsleeveorbulletP/N600304(1inchdia.shaft),P/N600466Thefollowingtoolsarenotnecessaryfordisassemblyandreassemblybutareextremelyhelpful.lSmallpropanetorch*Toolsavailable-byspecialorder-throughourservicedepartment.3GeneralPurposeMotorsSSeriesDisassemblyFigure23Removecapscrewsandsealwashersfromendcap(sealwashersusedon59,69and95cm3/r[3.6,4.2and5.8in3/r]displacementCleanlinessisextremelyimportantwhenrepairingthesemotors.motorsonly).Workinacleanarea.Beforedisconnectingthelines,cleanportareaofmotor.Removekeywhenused.Checkshaftandkeyslot,remove4Removeendcap.burrsnicksorsharpedgesandpolisharoundthekeyslot.Beforestartingdisassembly,drainoilfrommotor,thenplugportsand5RemovesealfromGeroler.thoroughlycleanexteriorofmotor.6RemoveGeroler-retainrollersintheouterGerolerring,seeFig.3.Althoughnotalldrawingsshowthemotorinavise,werecommendthatyoukeepthemotorintheviseduringdisassembly.Followthe7RemovesealfromGeroler,seeFig.3.clampingproceduresexplainedthroughoutthemanual.8Removedrivespacer(notusedon95and159cm3/r[5.8and9.7in3/r]displacementmotorsforthe-008and-009motorsandnotusedon-010motors).Figure11Placemotorinvise,clampacrossedgeofflangewithoutputshaftdown.Whenclamping,useprotectivedeviceonvise,suchasspecialsoftjaws,piecesofhardrubberorboard,seeFig.1.2Somemotorsmayhaveacasedrainplugintheendcap.Ifexternalcasedrainisnotused,itisnotnecessarytoreplacethesealFigure3unlessleakageoccurs.4GeneralPurposeMotorsSSeriesDisassemblyThescrewswillrequireapproximately34-45Nm[300-400Ib-in]oftorquetobreaklooseandapproximately11Nm[100Ib-in]torquetoremoveaftertheyarebrokenloose.DonotuseanimpactwrenchonLoctitedscrews,thismayresultinroundedheadsorbrokensockets.NOTE:Ifhighertorquethangivenaboveisrequiredtobreakthescrewsloose,applyheataccordingtothefollowinginstruction.WhenheatedtheLoctitepartiallymeltsandthetorquerequiredtoremovethescrewisgreatlyreduced.Followtheinstructionscarefully,andbecarefulnottooverheatandcausedamagetothemotor.Useasmallflamepropanetorchtoheatasmallareaofthehousing,wherethescrewenters,seeFig.6.ApplytorquetothescrewwithasocketwrenchFigure4graduallyasheatisappliedfor8to10seconds.Assoonasthescrewbreaksloose,removeheatfromthehousingandcontinueturningthe9Removespacerplatescrewuntilitiscompletelyremoved.10Removedrive,seeFig.4.11Removesealfromhousing.Clampacrossportsnotacrosshousing.Excessiveclampingpressurecausesdistorsion.Figure5Figure612Repositionmotorinvise.ClampacrossportsasshowninFig.5,14Removemotorfromvise.Placeoncleanflatsurface.Carefullyliftnotonsideofhousing.Donotovertightenjaws.Excessiveclampingflangefromhousingwithatwistingmotion.forcemaydistorthousing.13Removethe4capscrewsfromthemountingflange.ThesemotorsareassembledusingLoctiteonthescrewstoholdtheminplace.5GeneralPurposeMotorsSSeriesDisassembly15Thedustseal,pressuresealandoilsealwillcomeoffwiththeflange.Useasealremovertool,liketheoneshowninFig.7,toremovethedustsealandpressureseal,asshowninFig.8and9.Figure9Figure7Worknoseoftoolbetweenpressuresealandflange.Prysealpartway.Removetoolandrepeatatapoint180°away.Pushsealcompletelyoutofcavity,seeFig.8.Figure1016Removeoutputshaftfromhousing.Figure817Removebearingraceandneedlethrustbearingfromshaft.18Someolderhousingshaveplugs.Toremovetheplug,usea5mm[3/16inch]hexkey,insertedthroughportopening,topushthemout.6GeneralPurposeMotorsSSeriesReassemblyCheckallmatingsurfaces.Replaceanypartsthathavescratchesorburrsthatcouldcauseleakageordamage.Cleanallmetalpartsincleansolvent.Blowdrywithair.Donotwipepartswithclothorpapertowel,lintorothermattercangetintothehydraulicsystemandcausedamage.Checkaroundthekeyslotandchamferedareaoftheshaftforburrs,nicksorsharpedgesthatcandamagethesealswhenreassembling.Removenicksorburrswithahardsmoothstone(suchasanArkansasstone).Donottrytofileorgrindmotorparts.Note:LubricateallsealswithpetroleumjellysuchasVaseline.Usenewsealswhenreassemblingthemotor.Refertopartslist(No.6-125)forpropersealkitnumber.Important:Donotstretchsealsbeforeinstalling.CleanlinessisextremelyimportantinthesuccessfulapplicationofLoctite.Usethefollowingprocedurestoproperlycleanallparts.Figure11A.Washthehousingwithnon-petroleumbasesolventtoremoveoil,greaseanddebris.Petroleumbasesolventsmayleaveresidue19Ifyouremovedcheckvalves,orplug(s),replaceseal(s).LubricatedetrimentaltosuccessfulLoctiting.Payparticularattentionto4newseal(s).Installoncheckvalves,orplug(s).Carefullypushchecktappedholesontheflangeend.valves,orplug(s),inhousinguntilflushwithhousingface.Donotdamageseal(s).Note:FullycuredLoctiteresistsmostsolvents,oils,gasoline,20Lubricateoutputshaftwithcleanhydraulicoil,theninstallshaftinkerosene,andisnotaffectedbycleaningoperations.housing.B.Blowdrywithcompressedair.Cleananddrythetappedholes.Important:Donotpermitoiltogetintothe4tappedholes.Note:ItisnotnecessarytoremovethecuredLoctitethatissecurelyNote:Tohelpwithtimingprocedures,atimingdotismachinedonbondedinthetappedholes;howeveranylooseparticlesofcuredoutputshaft,seefigures18and19.Loctiteshouldberemoved.21Installneedlethrustbearingthenbearingraceonshaft.PullshaftC.WirebrushthescrewthreadstoremovecuredLoctiteandotherpartiallyoutofhousing,pushallthreepartsinhousingtogether.Thedebris.Discardanyscrewsthathavedamagedthreadsoracorroded,bearingracemustrotatefreelywheninposition.damaged,orroundedhead.D.Washthescrewswithnon-petroleumbasesolvent.Blowdrywithcompressedairjet.7GeneralPurposeMotorsSSeriesReassemblyImportant:Priortoinstallinghighpressureshaftsealitisnecessary23LubricateI.D.ofsealtubeandO.D.ofshaftpressuresealwithatobreakthesharpcorneroftheflangesealseat,seeFig.12.Uselightfilmofcleanpetroleumjelly.AlignsmallI.D.endofsealtubewith400gritpapertobreakcorner.sealseatinmountingflange.Installback-upringandpressuresealintube-lipsofsealfaceup-seeabove.Theninsertsealdriverintubetofirmlypush(byhandwithrotatingaction)sealinsealseat.Important:Afterinstallingsealinflange,examinesealcondition.Ifcut,damaged,orimproperlyinstalled,youmustreplaceitbeforecontinuingreassembly.MountingFlangeCross-section24Installdustsealinflange,seeFig.15.Pressthedustsealintoplacecarefully.Toeliminatedamagetorubberportionordistortionofmetalcontaineruseatool(flat-roundface35-41mm[1.37to1.62inch]diameter)whichprovidesproperguidingandpositioning.25Install1.94inch[50mm]I.D.sealinflange.Figure1222Cleanmountingflangeofallloosemetallicchips,particles,dirtorothercontamination,includingoil.Duringcleaning,visuallychecksealseatinmountingflangeforscratchesorothermarksthatmightdamagethepressureseal.Checkforcracksinflangethatmightcauseleakage,seeFig.12.Figure14Important:Ifapressuresealinstallationtoolisnotavailable,temporarilyinstallflangewithoutseals.Theninstall2capscrewstosecureflangetohousing.Installsealsinflange,andapplyloctite,afteryoureassembleGerotorendofmotor(seestep41thruCaution:DonotuseexcessiveamountofLoctite.45page11).26Apply3or4dropsofLoctiteadhesive(Loctiteno.601sealant)atNote:Ifyouhaveapressuresealinstallationtool,continuetopofthreadsineachof4holesinhousing,seeFig.14.Donotallowreassembly,startingwithstep23.partswithLoctiteappliedtosurfacetocontactanymetalpartsotherthantheirproperassembly.WipeoffexcessLoctitefromhousingface,usinganon-petroleumbasesolvent.DonotapplyLoctitetothreadsmorethan15minutesbeforeinstallingscrews.Ifhousingstandsformorethan15minutes,repeatapplication.NoadditionalcleaningorremovalofpreviousLoctiteisnecessary.Figure138GeneralPurposeMotorsSSeriesReassembly30Pourapproximately35ccofcleanhydraulicoilinoutputshaftcavity.Figure15Figure1627Beforeinstallingtheflangeandsealassemblyovertheshaft,place31Install90mm[3.59in.]I.D.sealinhousingsealgroove.Avoidaprotectivesleeveorbulletovertheshaft.Lubricatespacebetweentwistingseal.dustsealandpressureseal,aswellaslipsofbothseals,seeFig.15.installflange.Rotateflangeslowlywhilepushingdownovershaft.32Installdrive,observepropertimingprocedure(Fig.18).Becarefulnottoinvertordamagetheseals.33Placespacerplatecarefullyonthehousing,alignboltholes.28ClampmotorinviseasshowninFig.5,installdryscrewsandalternatelytorqueimmediatelyto28Nm[250lb-in].Ifyouuseprimer,allowtocurefor10-15minutes,withoutprimerallow6hoursbeforesubjectingmotortohightorquereversals.Onallotherapplicationsyoucanrunthemotorimmediately.Ifyouusenewbolts,makesuretheyarethecorrectlength,22mm[.875inch]underheadlength,seepartslistforcorrectpartnumber.Longerscrewswillnotpermitpropersealbetweentheflangeandhousing.Installkeyinkeyslotofshaft.GerolerEnd29Clamphousinginavise,Gerotorendup.SeeStep1forcorrectclampingprocedure.Important:Toaidinstallationofseals,applylightcoatingofcleanpetroleumjelly,suchasVaseline,tosealsbeforeinstalling.Important:Donotstretchsealsbeforeinstalling.Figure1734Install90mm[3.59in.]I.D.sealinGerotorsealgroove,seeFig.17.Avoidtwistingseal.35CarefullyplaceGerotoronthespacerplate,seeFig.17.Observepropertimingprocedure,seeFig.18.9GeneralPurposeMotorsSSeriesReassemblyTimingProcedureA.Alignshafttimingdotwithanybolthole.B.Installdrive.Forthe59and74cm©/r[3.6and4.5in3/r]displace-Reverserotationisobtainedbypositioninganystarvalley,ratherthanmentsonthe-010motors,installthewideendofthedriveintheanystarpoint,overthealignedbolthole.outputshaft.Installeitherendofthedriveintheoutputshaftforthe3-010motordisplacementsrangingfrom97to370cm/r[5.9to22.6ReverseRotationin3/r]C.Installspacerplate.Rememberwhichboltholewasalignedwiththeshafttimingdot.D.Placegerotoronwearplate,positioninganystarpointovertheboltholealignedwiththetimingdot.E.Rotategerotortofineupbolthole.Secarefulnottodisengagestarfromdriveordisturbgerotorseal.StandardRotationFigure1936Installdrivespacer(notusedon97and159cm3/r[5.9and9.7in3/r]displacementsonthe-008and-009motorsandnotusedatallon-010motors).Seefigure17.37Install90mm[3.59inch]I.D.sealinGerolersealgroove.Avoidtwistingseal.38Installendcap,seeFigures20and21.Figure1810GeneralPurposeMotorsSSeries43Installpressuresealflushagainstbearingrace,seeFig22.LightlyReassemblylubricatepressuresealO.D.39Installcapscrews(andsealwasherswhenrequired,seeinforma-tionbelow)inendcap.On97cm3/r[5.9in3/r]displacementmotorsorless,usesealwashers.Pre-tightenallscrewsto2-5Nm[15-40lb-in].MakesureGerolersectionsealsareproperlyseatedbeforetorquingscrews.Thentorquescrewsto23Nm[200lb-in]insequence,asshowninFig.21.On120cm3/r[7.3in3/r]displacementmotorsorlarger,omitsealwashers.Pre-tightenallscrewsto2-5Nm[15-40lb-in].MakesureGerolersectionsealsareproperlyseatedbeforetorquingscrews.Thentorquescrewsto34Nm[300lb-in]insequence,asshowninFig.21.PressureSealLipsTowardRaceFigure2244Placeasealsleeveorbulletovershaft.Twistflangedownshaftuntilflushagainstpressureseal.Thepressuresealmustenterintoseatevenlyandgradually.Install4capscrews.Graduallyandevenlyfingertightencapscrews(crisscrosspattern).ThenuseahandsocketwrenchtolightlysnugtightenscrewsuntilflangeisflushagainsthousingDonottighenscrewsmorethanonefullrotationatatime(crisscrosspattern).45UseahandtorquewrenchtograduallyandevenlytightencapFigure20screws(crisscrosspattern)untiltheyreach28Nm[250lb-in].Seeimportantinformationbelow.Important:Donotuseairsocketwrenchoncapscrewsforthistypeofsealinstallation.Important:Properpressuresealinstallationisimportant.Youmustremovecapscrewsandflangetoexaminesealcondition.Ifyouhavecutordamagedthepressureseal,youmustreplaceitwithanewone.Ifsealisingoodconditioncontinueflangereassembly—startingwithprocedurestep24,page8.BoltTorquingSequenceFigure21Note:Steps41through45covermountingflangesealinstallationwithoutusingasealinstallationtool.40Clampmotorinvisewithoutputshaftup,seeFig.23.Removecapscrewsandflange.41Preparesealseatofflange,seestep22.42LubricatedustsealO.D.Installdustsealinflange.Makesuredustsealisflushwithflange,seestep24.Figure2311GeneralPurposeMotorsSSeriesForAdditionalLiteratureContactEatonCorp.HydraulicsDivision15151Highway5EdenPrairie,MN55344.lSpecificationsandperformanceData,CatalogNo.11-885lReplacementPartNumbersandKitInformation:SSeriesMotors—PartsInformationNo.6-125.HowtoOrderReplacementPartsEachOrderMustIncludetheFollowing:1.ProductNumber4.PartNumber2.DateCode5.QuantityofParts3.PartName103-1000-XXXNumbers1001through1999StandardModels103-2000-XXXNumbers2001through2999MotorswithCaseDrainPortEatonCorporationEatonLtd.EatonGmbHHydraulicsDivisionHydraulicsDivisionHydraulicsProductsQualitySystemCertified15151Hwy.5Glenrothes,FifeAmSchimmersfeld7ProductinthiscatalogaremanufacturedEdenPrairie,MN55344Scotland,KY74NW40880Ratingen,GermanyinanISO-9001-certifiedsite.Telephone612/937-9800Telephone01-592-771-771Telephone02102-406-830Fax612/937-7130Fax01-592-773-184Fax02102-406-800CopyrightEatonCorporation,1987,1993,1994,1995,and1996AllRightsReservedFormNo.7-116PrintedinUSA