Gradall Crawler Vendor Service Manual

XL SERIES CRAWLER
MAINTENANCE MANUAL
Form No. 29635

Original Issue 3/97
Rev. 9/00
MAINTENANCE MANUAL
XL SERIES CRAWLER UNDERCARRIAGE
Table of Contents
Page
Introduction
Nomenclature
Track Adjustment
Shoe Contact with Rock Guard
Crawler Travel Speed
Crawler Tracking
Track Chain
Track Rollers
Idler Roller with Track Tension and
Adjuster Components
IX. Drive Sprocket
X. Miscellaneous
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
(ii)
1
3
5
6
7
8
15
19
24
26
NOTE! High Pressure denotes 10,000 psi gauge

Low Pressure denotes 1,000 psi gauge
Form No. 29635 3/47
(i)
MAINTENANCE MANUAL
XL CRAWLER UNDERCARRIAGE
Introduction
Orientation:
Right, left, front and rear relate to the direction of a person sitting in the upperstructure cab. The front of the
machine is the idler roller end. The excavating (working) function should always be performed over the front
to minimize track component wear.
Related Materials:
Other manuals related to your machine should be reviewed for information about a specific subject
other than XL CRAWLER UNDERCARRIAGE maintenance.
Other manuals available for your machine:
Operators Manual
Service Manual
Safety Manual
Sales Literature
Parts Manual
Brochures
Miscellaneous Vendor Manuals covering specific components
Form No. 29635
3/97
(ii)
Introduction (continued)
This Manual covers technical repair and maintenance information for the CRAWLER UNDERCARRIAGE of the
XL SERIES GRADALL
Charts showing component dimensions, part numbers, wear percentage, fastener torque values, hydraulic
hose and fitting torque values and lubrication capacity information are included.
Information about track chain adjustment, repair and replacement is also supplied.
This Manual does not cover machine operation or the hydraulic system. Refer to appropriate manuals for
that information.
Familiarize yourself with this Manual and its contents. Should you have questions concerning information
supplied or a specific machine, please contact your GRADALL distributor for assistance.
Safety
The following symbols are used to call your attention to safety notices.
DANGER
DANGER: This symbol indicates an extreme hazard which could result in high
probability of death.
WARNING
WARNING: This symbol indicates a hazard which could result in death or

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

damage to equipment or property if proper precautions are not taken.
DAILY:
Read and adhere to all safety notices placed on the machine and in the various technical and operators manuals.
Clean the machine as required.
Be sure all grab handles, steps, and walking areas are clean and clear.
Be sure the fire extinguisher works.
Check that all safety decals are in place as when the machine was received new.
Be sure all safety and operators manuals are with the machine.
Report any safety hazard to the correct personnel.
DO NOT operate the machine in an unsafe manner.
DO NOT operate the machine if you are unfamiliar with the controls.
DO NOT operate the machine if you are under the influence of alcohol or drugs.
Be certain controller shut-off safety switch functions properly when the operators seat handle is raised.
WARNING
Form No. 29635 3/97
DO NOT remove track tensioning hydraulic cylinder fitting while it is pressurized. Relieve
pressure by loosening the fitting one or two turns until grease escapes through the vent
slot and pressure is relieved. Refer to the warning decal on the inside of the side frame
cover protecting the track tensioning device.
(iii)
MAINTENANCE MANUAL
I. Nomenclature
FIGURE 1
GRADALL CRAWLER UNDERCARRIAGE
This Manual covers the undercarriage mechanical running gear. Components such as planetary drive, hydraulic
drive motor and crawler brakes are not covered. Refer to the respective manual for information on these
components. The undercarriage frame (carbody and side frame) is only covered in welding repairs.
A quick reference chart is supplied as an aid to find major components in their respective parts manual.
Refer to the contents page for specific components covered in this Manual.
How to extend Undercarriage life
l
l
l
l
Dig only with the attachment over the idler end of the tracks. This gives even pin and bushing
contact, reducing wear. An attachment working over the sprockets will result in overloading the
surfaces between the sprocket and track bushing.
Travel in the forward position with the sprockets at the rear end of the machine. Travelling in reverse causes
excessive wear on the sprockets and chains.
When turning, utilize both tracks. Using power to one track only causes the opposite track to drag,
wearing components more rapidly.
Keep back and drive components clean and free of mud and debris.
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MAINTENANCE MANUAL
I. Nomenclature (continued)
l
Perform daily inspections, checking for loose bolts, leaking seals, structural damage, correct track adjustment
and any abnormal wear. Report problem areas to appropriate personnel.
Operate the machine in a smooth professional manner, especially over obstacles or rough terrain. This will
usually prevent premature roller and component wear and reduce the possibility of track shoe bending.
Always park the machine on level ground. If parked on an incline or uneven terrain, the roller seals could
become deformed or damaged resulting in lubricant loss. Without lubricant the internal parts of a roller will
be destroyed within hours.
Keep the machine lubricated per lube chart.
Replace or rebuild track chain components as required. Refer to the Track Chain section of this Manual for
specific component information.
Keep a supply of metric fasteners in stock to replace broken or lost components.
When replacing bolts, nuts, hydraulic hoses and/or hydraulic fittings, torque them to the values shown in the
torque charts on pages 28-30 of this Manual.
Form No. 29635 3/97
II. Track Adjustment

FIGURE 2
TRACK ADJUSTMENT CHECK
Proper track adjustment is achieved when the link assembly is properly tensioned. This condition is reached
when the maximum sag between the top carrier roller and the drive sprocket matches the dimension A
shown on Figure 2. The allowable sag for your machine is as follows:
XL 5200-35mm-1.375 in.
XL 4200-35mm-1.375 in.
XL 2200-20mm-0.781 in.
Track Adjustment Procedures:
l Clean track components so foreign material does not obstruct the tensioning assembly
from full free movement.
l
Install a straight edge on the track and measure sag per Figure 2.
If tightening adjustment is required, add grease to the tensioning cylinder until the proper
dimension A in Figure 2 is achieved.
TO ADD GREASE TO THE TENSIONING CYLINDER, PROCEED AS FOLLOWS:
FIGURE 3
SIDE FRAME TRACK TENSIONING DEVICE COVER
FIGURE 4
WARNING DECAL
the track tensioning device cover from the side frame. See Figure 3. Follow the warning decal
instructions on the inside of the cover. See Figure 4.
l Remove
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MAINTENANCE MANUAL
II. Track Adjustment (continued)

FIGURE 5
BUTTON HEAD HYDRAULIC FITTING
FIGURE 6
FILL VALVE (TRACK TENSIONING CYLINDER)
Attach the button head hydraulic fitting (furnished in the tool kit) to the fill valve that is screwed
into the tensioning cylinder. See Figure 5 and Figure 6.
NOTE! The XL 5200 also has a relief valve installed in the tensioning cylinder.
l
Pressurize the cylinder until the proper dimension A is achieved. See Figure 2.
Reinstall the track tensioning device cover to the side frame. See Figure 3.
IF THE TRACK TENSION IS TOO TIGHT AND NEEDS LOOSENING PROCEED AS FOLLOWS:
Remove the track tensioning device cover from the side frame. See Figure 3. Follow the warning decal
instructions on the inside of the cover. See Figure 4.
Carefully back out the hydraulic fill valve from the tensioning cylinder until lube starts to escape
from the relief slot machined in the threads. See Figure 5 and Figure 6.
Release the amount of lube necessary to achieve proper dimension A in Figure 2 for your machine.
FIGURE 8
FILL VALVE AND BUTTON HEAD FITTING INSTALLED
IN TENSIONING CYLINDER
FIGURE 7
TENSIONING CYLINDER FILL VALVE WITH
BUTTON HEAD FITTING
Figure 7 and Figure 8 show the tensioning cylinder fill valve and the button head fitting
NOTE! that fits to it. Be certain you understand how to install the buttonhead fitting to the fill
valve (one-way check valve) before attempting adjustment.
Reinstall the side frame cover.
WARNING
Form No. 29635 3/97
Do not remove any parts until all pressure in the tensioning cylinder has been relieved. Serious
injury could occur. Refer to the decal on the undercarriage side frame tensioning cylinder cover.
II. Track Adjustment (continued)

Improper Adjustment Hazards:
TRACKS TOO TIGHT:
If track is too tight, excessive friction will cause a reduction in machine performance and may cause
accelerated wear of rolling track components.
TRACKS TOO LOOSE:
If track is too loose, component service life is drastically reduced. Loose tracks easily become misaligned and
may jump off the sprockets when the machine is turned. A loose track may also jump sprocket teeth
causing
damage or premature wear. At best, loose tracks make it difficult to travel in a straight line.
NOTE! Both tracks must be adjusted equally to ensure proper travel performance.
III. Shoe Contact with Rock Guard

Contact with the rock guard may result in wear on a portion of the leading edge. The track chain may flex up
between rollers as the machine travels over the ground. The amount that the chain can flex in this direction is
increased when internal pin and bushing wear occurs. As the chain flexes up, the leading edge of the shoe may
contact the rock guard. (See Figure 9). Also, rail and track roller tread wear reduces the clearance between the
track shoes and the rock guards. This would increase the possibility of contact. Normal contact may also occur if
the track chain is tipped up on one side by rough terrain.
This type of wear does not affect the function of the track shoe and, therefore, is a minor wear pattern. It does,
however, reduce the bending strength of the shoe.
FIGURE 9
SHOE CONTACT WITH ROCK GUARD
Form No. 29635 3/97
MAINTENANCE MANUAL
IV. Crawler Travel Speed

Adjustment for crawler undercarriage travel speed is performed of the control valves. See Figure 10. There
are stroke limiters provided on each crawler propel valve end cap. Use the following tests to set freerunning speed and actual travel speed. A stopwatch and point (for marking the tracks) will be required
for these tests.
Before checking travel speed, be certain the tracks, chains, and rollers are free of mud, and other
debris that could interfere with achieving correct test results. Check track tension before testing travel speed. If
track tension is not correct, perform track adjustment procedures outlined on pages 3 and 4 of this Manual.
Travel Speed Testing and Adjustment Procedures:
1.
Rotate the upperstructure so the boom is perpendicular to the right-hand track. Place the bucket on the ground
with the boom extended. Apply down pressure to the boom to raise the right hand track off the ground. Paint a
stripe on the track to be used as a reference point.
2.
Set the crawler speed to High. Push the right-hand forward travel pedal. When the paint stripe reaches your
desired location, start the stopwatch and time the track for one complete revolution. The correct speed is as
follows: XL 5200: 8.6 to 9 seconds (27.9 RPM sprocket speed). XL 4200: 7.8 to 8.2 seconds (27.9 RPM sprocket
speed). XL 2200: 3.9 to 4.3 seconds (55.7 RPM sprocket speed).
3.
If travel speed needs corrected, remove the plug from the rear stroke limiter. Insert an allen wrench in the stroke
limiter screw. Loosen the stroke limiter housing and adjust it to achieve the correct travel speed. Turning the
stroke limiter screw clockwise decreases travel speed, turning it counter clockwise increases travel speed. Re-test
travel speed after adjustment. See Figure 10.
4.
Repeat test for right-hand reverse travel using the front stroke limiter. After this travel speed is set, carefully raise
the boom to lower the right hand track to the ground.
5.
Rotate the upperstructure so the boom is perpendicular to left-hand track. Repeat forward and reverse track
speed test for the left hand track using steps 1 thru 4.
6.
After free-running speed has been checked, mark off a level, linear distance of 100 feet. Set the crawler undercarriage for high speed and enter the 100-foot marked course travelling straight and at full travel speed
forward. Begin timing as the machine enters the course and end timing when it exits. Correct travel speed is as
follows: XL 5200: 30.3-30.9 seconds. XL 4200: 27.8-28.4 seconds. XL 2200: 19.5-20.1 seconds.
NOTE!
7.
If travel speed is slower than the above times and free-running speed was tested correctly, do
not increase track speed to achieve the above times. Use free-running speed as the maximum speed
for the crawler undercarriage.
Repeat step 6 for reverse travel.
Form No. 29635 3/97
IV. Crawler Travel Speed (continued)

FIGURE 10
CRAWLER SPEED ADJUSTMENTS
V. Crawler Tracking
Crawler Undercarriage Tracking
The crawler undercarriage is allowed a small deviation from straight travel. If this deviation is excessive,
it can be adjusted using the crawler propel valve stroke limiters. Whenever tracking is adjusted, the freerunning travel speed of the undercarriage must be checked to ensure it does not exceed specifications
for the model being tested. It may be necessary to slow one track, rather than speed up the other.
1.
To Check Undercarriage Tracking Proceed as Follows:

Mark off a level, linear distance of 100 feet. Set the crawler undercarriage for High speed. Enter the 100-foot
marked-off course straight and at full travel speed forward.
2.
After completing the course, measure the machines path of travel for deviation from a straight line. Maximum
allowable deviation is 10 feet. If free-running speed has been checked and is correct, it is best to slow the fast
track when adjusting tracking. The stroke limiter adjustment screw should not be adjusted more than 1/8 of a
turn before retesting. The stroke limiter adjustment is very sensitive. Use the rear stroke limiter to adjust forward
travel.
3.
After forward travel tracking test is complete, repeat for reverse travel. Use the front stroke limiter to adjust for
reverse travel. See Figure 10.
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MAINTENANCE MANUAL
VI. Track Chain

FIGURE 11
TRACK PIN & BUSHING
The track chain assembly known in the industry consists of a series of links, pins and bushings on which the track
shoes are bolted. The chain contacts the drive sprocket on one end of the machine and the idler roller chain
tensioning assembly on the other end. As the sprocket turns, the teeth contact the bushings pulling them around
the circumference resulting in machine travel.
The links are fastened together by pins and bushings which are sealed. See Figure 11 and Figure 18.
The chain must be installed with the pin end of the links facing the back of the machine at ground level.
To split open a track, first locate the master pin. It has a (machined center) countersink in the center of each end.
See Figure 18. Then position the track so it is accessible. Use a portable press to push the pin out. The chain is
now broken apart and both ends are free.
WARNING
Stay clear of the end of the chain to prevent injury should it roll uncontrolled to the
ground. We recommend you use a come-a-long or similar fastening device to lower the
end of the chain to the ground.
Reverse the procedure for reassembly.
Form No. 29635 3/97
VI. Track Chain (continued)

The accumulated operating (traveling) hours on the machine result in link wear. Replace whenever the 100%
value is reached. Allowable link wear is per Table 1:
FIGURE 12
TRACK LINK
TABLE 1
TRACK LINK WEAR PERCENTAGE DATA
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MAINTENANCE MANUAL

Track Shoes
The standard track shoes (pads) used on the GRADAlL crawler machines are the triple grouser type. This
design gives a lower penetration into the surface, reduces turning resistance, improves maneuverability
and reduces loads on other undercarriage parts.
Other style track shoes are also available.
To minimize shoe bending or breaking, do not use a wider shoe than is required. It is important to keep
the track bolts properly torqued. (Refer to bolt torque chart on pages 28-30 of this Manual)
Approximately every 100 hours the bolt torque should be checked. Visually check for loose or missing bolts
at the start of each operating shift. If track shoes show a tendency to bend or break, the shoes may be too
wide for the working surface.
Maximum back shoe wear of 100% (See Table 2 for values applicable to your machine) is
allowable if the machine is normally working on medium soft ground. Operating on rocky ground the
shoes must be replaced when the wear is 75%. (Second column from right, Table 2.)
FIGURE 13
TRIPLE GROUSER SHOES
TABLE 2
TRIPLE GROUSER SHOE WEAR PERCENTAGE DATA
Form No. 29635 3/97
10

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

Track Bushing
The track bushings fit into the counterbore of each link. There is one bushing per link set. The track pin fits
through the bushing.
The O.D. of the bushing contacts the teeth of the drive sprocket during travel. This results in bushing wear at
the sprocket side only. This wear along with pin wear is a major factor in causing looseness and damage to
the chain by increasing pitch length.
Outside wear of the bushings is of three types: Radial Wear, Forward Drive Side Wear, and Reverse Drive Side
Wear. (See Figure 16) Measurements should be taken at each position; use the one which indicates
maximum wear. (Refer to Table 3).
FIGURE 16
TRACK BUSHING WEAR
TABLE 3
OUTSIDE BUSHING WEAR
Form No. 29635 3/97
12

FIGURE 17
MASTER PIN
MACHINE CENTER
(COUNTERSINK)
Master Pin and Bushing

A master pin and bushing is used on each track. These components are the ones used to take the track apart and
put it together. See Figure 17. The master pin and bushing wear more rapidly than do other pins and
bushings. This is because the bushing does not extend into the counterbore of the link.
The master pin can be identified by the countersink (center) machined in the center of each end.
A portable press is used to remove the master pin.
!
WARNING
Once the master pin is removed, the track may roll uncontrolled to the ground. To avoid
injury, stay clear.
FIGURE 18
TRACK PIN SEALS
The track chain link is sealed at each end of the track pin. This design helps guard against contaminants, a major
source of premature wear. The seals must be installed. See Figure 18.
When the pins and bushings are assembled they must be well lubricated.
Track Bolts
The track bolts have special wear-resistant heads, self-locking, square nuts and rolled threads. These bolts meet
American standard Grade 8 and European standard 12.9 class.
Torque values are found in the torque chart. See Pages 28-30.
The bolts should be randomly checked for torque approximately every 100 hours. Check for loose or missing bolts at
the start of each operating shift.
Form No. 29635 3/97
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MAINTENANCE MANUAL

When To Repair Track Group
Once you determine exactly when to replace each worn part of your undercarriage, you have maximized your
opportunity to exact the most economical use of your undercarriage.
This Manual contains tables showing the maximum wear limit for each track moving part. If these limits are
observed, you will realize economical performance without costly expenses resulting from component
damage, replacement parts and machine downtime.
For measurement of component wear, a few simple tools are needed: flexible tape, small caliper, large caliper,
depth gauge, steel ruler and straight edge.
Links, Pin and Bushing Wear Measurement
To establish the average wear measurement, choose a length of 4 sections of link assembly on top of the
undercarriage in a well tensioned zone. Do not include master pin and link in the four sections of link
measured. See Figure 19 and Table 4.
Once the wear measurement reaches the 100% limit the pins may be turned 180 for extended life. If this
operation has been previously performed the worn parts must be replaced.
FIGURE 19
FOUR SECTIONS OF THE LINK ASSEMBLY
TABLE 4
WEAR DATA: 4 SECTIONS OF THE LINK ASSEMBLY
Form No. 29635 3/97
14
VII. Track Rollers

FIGURE 20
TRACK ROLLER
The track rollers used on the XL SERIES GRADAlL CRAWLER are sealed units that normally require no resealing
or refilling (unless they have been damaged). The rollers are filled with SAE 30 or SAE 40 weight oil. To fill
the roller, remove the fill plug from the body and fill with the quantity of oil shown for your machine in
Table 5.
The XL 5000 and XL 4000 use the bottom roller design for the top and bottom of the track. The XL 2200
uses a bottom design on the bottom of the track and a carrier design roller for the top of the track. Refer
to the quick reference chart or the applicable parts manual for part number identification.
TABLE 5
TRACK ROLLER LUBE CAPACITY CHART
Form No. 29635 3/97
15
MAINTENANCE MANUAL
VII. Track Rollers (continued)

Roller Seals
If the seal group is being replaced, use new parts only. Used seals will most likely fail shortly after rebuild.
Installation procedure for roller seals is as follows:
1.
2.
3.
4.
5.
The mating surface where the seals contact must be dry and clean, free of dirt, nicks and burrs.
6.
Fill roller with lube. See Table 5.
Install O-ring on the roller shaft.

Install the seal group into the roller shell seat. Remove the plastic band holding the rings together.
Press the collar onto the roller shaft and lock in place with the dowel.
Invert the roller assembly and perform steps 1 through 4.
FIGURE 21
ROLLER SEALS
Form No. 29635
16

Track Roller Disassembly (See Figure 21)
1.
2.
3.
4.
Remove lube fill plug and dump lube into a container.

Press dowel pin out of collar.
Remove seals and shaft.
Press out bushings.
Track Roller Assembly (See Figure 21)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Install bushings into roller shell.

Install collar to roller shaft.
Install dowel pin through collar and shaft.
Install O-ring in roller shaft.
Install seal group in roller shell seal seat.
Insert collar and shaft into shell until collar bottoms to the seal group.
Invert roller 180.
Complete component assembly as in steps 2 through 6.
Fill Roller with lube. See table 5.
Form No. 29635 3/97E
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MAINTENANCE MANUAL

Bottom and Carrier Track Rollers
The rail diameter of the bottom and carrier roller for your machine when it was new is shown in Table 6 and
Table 7. Whenever the wear percentage reaches the 75% range the roller diameter should be resurfaced to size
or the roller replaced.
The track roller rail surface hardness is Rc 55.
FIGURE 22
BOTTOM ROLLER
FIGURE 23
CARRIER ROLLER XL 2200
TABLE 6
BOTTOM ROLLER WEAR PERCENTAGE DATA
TABLE 7
CARRIER ROLLER WEAR PERCENTAGE
Form No. 29635 3/97
18
VIII. Idler Roller with Track Tension and Adjuster Compartments

FIGURE 24
IDlER ROLLER:TYPICAL
The idler roller assembly is located at the front of each side frame. Major components are Idler Roller,
Tensioning Spring, Hydraulic Adjusting Cylinder, Idler Slides and Connecting Bracket.
This assembly acts as a shock absorber for the track system. It compensates for shock loads (caused by
large rocks, uneven terrain, etc.) imposed by momentarily adjusting the chain pitch. Compensation is accomplished
by the tensioning spring and hydraulic cylinder collapsing the required amount, thus minimizing the chance
of chain breakage.
The XL 5200 hydraulic adjusting cylinder is equipped with a relief valve to assist in accepting major
shock loads that could be imposed on this size machine. The relief valve will relieve lubrication to
compensate for excessive shock loads. Should this occur very often it may be necessary to recharge
the cylinder with lubricant once the travel cycle returns to normal.
Form No. 29635 3/97
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MAINTENANCE MANUAL
VIII. Idler Roller with Track Tension and Adjuster Components

(cont.)
FIGURE 25
IDLER ROLLER
The idler roller has two outside rails which is the area that the track links make contact. These rails are
hardened to Rc 55.
The rollers are lifetime lubricated and under normal working conditions no further lubrication maintenance
is required. The idlers should be randomly checked while working to protect against destruction should a
seal be damaged.
To install lubrication we recommend the use of a low pressure pump with a nozzle on the end that will fit
through the fill hole in the idler body. Use SAE 30 or SAE 40 oil at capacities for your machine. See Table 8.
TABLE 8
IDLER ROLLER LUBRICANT CAPACITY
Form No. 29635 3/97
20
VIII. Idler Roller with Track Tension and Adjuster Components (cont.)
Idler Roller Disassembly (See Figure 25)
ASSUMPTION: RECOIL COMPONENTS HAVE BEEN REMOVED AND THE ROLLER IS FREE.
1.
Remove one of the dowel pins that fasten the bracket to the shaft.
2.
Remove the remaining components which are now free of the shaft.
3.
Press out the bushing. (The bushing can only be removed by use of a vertical press with correct tooling.)
4.
If necessary, remove the remaining dowel pins and bracket.

Idler Roller Assembly (See Figure 25)
1.
2.
3.
4.
5.
6.
7.
Press the bushings into the idler shell.

Mount a bracket on to the shaft.
Insert seal group into the idler shell seal seat.
Install O-ring on the shaft.
Insert the complete sub assembly in the idler shell to the point where it bottoms the seal group.
Invert the idler and assemble components as in steps 1 through 4.
After loose assembly press tightly together using a vertical press.
NOTE! The seal group is assembled the same as in the bottom rollers. See Figure 21.
Idler Roller and Track Tensioner Removal and Replacement to the Side Frame
!
Serious injury could result if the pressure is not relieved from the tensioner and recoil system.
WARNING See decal on the side frame cover and Track Adjustment section of this Manual.
To remove pressure from the cylinder, carefully back off one or two turns on the fill fitting. (Refer to Track
Adjustment section of this Manual.) As soon as lube starts to come out the vent hole STOP backing off the
fitting. Once pressure is relieved it is safe to remove the roller and tensioner assembly.
It will be necessary to collapse the tensioning cylinder fully for reassembly of the group.
See Table 9 for the part number and stroke of the cylinder for your particular machine.
TABLE 9
IDLER ROLLER TENSION CYLINDER
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MAINTENANCE MANUAL
VIII. Idler Roller with Track Tension and Adjuster Compartment (cont.)
Track Tension and Idler Roller Disassembly (See Figure 24)
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.
7.
8.
Relieve all pressure from the track tensioning cylinder. See Figure 3 and Figure 4.
Carefully separate the track chain and lay it on the ground.
Remove the recoil device group (refer to the correct page in the Parts Manual for your machine).
Remove the track tension group (refer to the correct page in the Parts Manual for your machine).
Remove the two (slide brackets) support groups and idler pin from the side frame.
Remove idler roller from the machine.
Examine all fasteners and seals for damage. Replace any damaged component.
Track Tension and Idler Roller Reassembly
Clean, lubricate, and check all components for damage.
Reassemble idler roller with support group and fork and install into side frame (refer to Parts
Manual for parts required).
Install track tension group (refer to Parts Manual for parts required).
Torque all fasteners to correct value.
Reassemble track chain to side frame and lack master pin and bushing as required.
Using button head coupling (8381-3109) supplied in the GRADALL Tool Kit, pressurize the tensioning
cylinder to achieve the correct track adjustment. (Refer to Track Adjustment section of this Manual.)
Install cover over the opening in the side frame for the valve that is used for the tensioning cylinder adjustment.
Check that the WARNING for track adjustment is in place. If it is not on the inside of the side frame cover,
(installed at step 7) or is illegible, notify the correct personnel to have it replaced immediately.
Form No. 29635 3/97
22
VIII. Idler Roller with Track Tension and Adjuster Components (cont.)
Idler Roller Rail Weld Refacing
TABLE 10
WEAR PERCENTAGE DATA
Figure 26 and Table 10 show the allowable wear on the rail height of the idler roller. A good undercarriage shop
has the ability to rebuild (reweld) the roller to its original dimensions. When wear percentage reaches 100% the
idler roller must be rebuilt or replaced.
FIGURE 26
FRONT IDLERS
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MAINTENANCE MANUAL
IX. Drive Sprocket

The drive sprocket is sized to provide proper travel performance for the model machine on which it is used. It is
bolted to a gear box that is also sized for correct performance. The drive sprocket always has an uneven number
of teeth. As they rotate the drive chain is engaged which results in machine travel.
The six major types of drive sprocket wear are:
1.
Drive Chain Wear --- when operating forward.
2.
3.
4.
5.
Reverse Drive Side Wear --- when operating in reverse.

Climbing Wear --- result of increased track pitch.
Root Wear --- when bushings slide from side to side.
Rotative Wear --- when bushings rotate as they leave (forward) or enter (reverse) the sprocket.
Reverse Drive Side Tip Wear --- when sprocket pitch is greater than track pitch.
The drive sprocket is cast of special manganese steel hardened to Rc 55. If it is reconditioned by welding it must
conform to the dimensions of a new sprocket.
Table 11 gives the new and allowable wear tolerances of the sprocket on your machine.
TABLE 11
NEW DRIVE SPROCKET DIMENSIONS
FIGURE 27
DRIVE SPROCKET
Form No. 29635 3/97
24
IX. Drive Sprocket (continued)

Wear on the sprocket is very difficult to measure. As the machine works, wear takes place in such a way that
no trace of the original teeth are left for use as a measuring point. Sprockets should be rebuilt or replaced
whenever wear percentage reaches 100%.
`
Wear is never uniform, so measurements should be taken at different points on the sprocket teeth. See Figure 18.
Use the area showing the most wear as your gauge for determining wear percentage on Table 12.
Dimension 0F from Table 11 is the original diameter of your respective sprocket. Dimension 0G is the
dimension to the centerline of the bushing for your back as it lays against the root of the sprocket tooth
when new.
TABLE 12
DRIVE SPROCKET WEAR PERCENTAGE
FIGURE 28
TOOTH DEPTH
Drive Sprocket Removal from Drive Mechanism

To remove the drive sprocket from the machine, proceed as follows:
Release pressure from the track tensioning device per safety decal instructions (Refer to track
Adjustment section of this Manual.)
1.
2.
3.
4.
5.
Separate the track chain at the master pin and bushing. See Figure 17.
Carefully lay the drive chain on the ground. Use good SAFETY practices to prevent injuries.
Attach lifting or holding device to the sprocket to prevent uncontrolled falling once it is free of the machine.
Remove the socket head capscrews holding the weldment to the planetary drive.
Lift the sprocket to the work area as required.
Form No. 29635 3/97
25
MAINTENANCE MANUAL
IX. Drive Sprocket (continued)

Drive Sprocket Reassembly to Drive Mechanism
To reassemble the drive sprocket, proceed as follows:
1.
2.
3.
4.
5.
6.
7.
Clean all areas of the side frame and drive mechanism where the sprocket fits.
Use Never-seez on mounting surfaces (pilots).
Lift drive sprocket into place (pilot mounting surface).
Install mounting capscrews (socket head metric).
Torque mounting screws to correct value as required. Refer to Table 13 and 14.
Lift track chain in place and fasten together at the master pin and bushing.
Adjust the track chain to correct specifications.
X. Miscellaneous
Towing
If power is lost to the crawler drive and it becomes necessary to tow the unit proceed as follows:
1.
2.
3.
4.
5.
6.
7.
Remove the sheetmetal guards from the drive mechanism as required for access to the planetary drive.
Remove the planetary drive cover mounting socket head capscrews and store in a safe place for reuse.
Remove the sun gear from the planetary drive and store in a safe place for later reuse.
Reinstall the planetary drive cover.
Perform steps 1 through 4 on the opposite track.
Install towing chain and/or cable to towing area on the carbody.
Carefully tow the machine to the area designated.
When the machine is to be put back into service, it will be necessary to reinstall the removed sun gear to the
planetary drive. Retorque fasteners to correct value per the torque chart. Reinstall any sheetmetal protective
covers removed. Lubricate the machine per specifications before resuming normal operations.
Undercarriage (Carbody and Side Frames)
The undercarriage (carbody and side frames) of the GRADALL CRAWLER is designed correctly for the size machine
it is mounted under. The integrity of the design is assured during manufacture by the use of intricately designed
welding and machining fixtures.
Welding Repairs
Should welding repairs be required, adhere to the following procedures:
1.
2.
Disconnect the battery leads to prevent electrical component damage.
3.
Use welding rod or wire conforming to AWS 7018 low hydrogen process.
Position the ground clamp adjacent to the area being welded. This will prevent arcing between components such
as bearings, etc. which could cause damage to them. Do not ground through rotating parts.
Form No. 29635 3/97
26
X. Miscellaneous (continued)
Piston Motor
A bent axis piston type motor is fastened to the planetary drive at the sprocket end of the side frame. It can be
shifted from low speed to high speed or vice versa as required. Refer to the Crawler Hydraulic Schematic and
the Vendor Service Manual for more detail.
Planetary Drive and Crawler Holding Brake
A planetary gear reduction box and disc brake assembly is connected to the drive sprocket. The brake is
normally set. It is released by hydraulic pressure whenever the travel cycle is activated and remains
disengaged as long as the travel circuit is pressurized. The brake is not a dynamic stopping brake. It is a holding
brake only.
Track Guides
The function of the track guides bolted to the side frame is to keep the track chain in line. It also may keep the
track chain from jumping the sprockets when turning if the chain pitch is outside the allowable tolerances.
Planetary Drive and Crawler Holding Brake (continued)
The planetary gear box operation is explained in a separate Manual supplied by the Vendor. Refer to that
manual for information on the function of this assembly. Refer to the lubrication chart for the type and capacity
of the gear box.
Bolt Torque Charts
The following bolt torque charts (Table 13 and 14) covering English and Metric fasteners are the ones used by
GRADALL Ratings are for lubricated fasteners. Do not exceed the allowable rating. An overtorqued bolt in most
cases will fail as rapidly as an undertorqued one. Bolt sizes and torque values are shown in most cases with the
description given in the GRADALL Parts Manual.
NOTE !
Form No. 29635 3/97
To check GRADALL torque values, set the torque wrench at the minimum rated torque value and
tighten fastener. If the torque wrench releases before the fastener moves, assume that the fastener
torque is correct.
27
MAINTENANCE MANUAL
TABLE 13
BOLT TORQUE VALUES FOR METRIC FASTENERS
Form No. 29635 3/97
28
TABLE 14
BOLT TORQUE VALUES AND TOLERANCES FOR LUBRICATED ENGLISH BOLTS
NOTE!
Form No. 29635 3/97
Never-seez to be used on master link pin before assembly torque pad bolts over
master link to 185 ft. lb. +10 -0
29
MAINTENANCE MANUAL
Hydraulic Hose and Hose Fitting Torque Charts
To minimize leakage, the hydraulic hoses and hydraulic hose fittings are torqued to specified values. Whenever a
hose or fitting is removed, it should be retorqued to the correct value when it is replaced. Refer to the hydraulic
hose and hydraulic fitting torque charts (Table 15, Table 16 and Table 17) for correct values used on the
GRADALL product line.
TABLE 16
TABLE 15
*Torque values with an asterisk are from JIC Fitting Torque Chart.
TABLE 17
ORS FACE SEAL TUBE/HOSE TO FITTING
Form No. 29635 3/97
30
Tools
Standard heavy equipment maintenance tools are required to work on the GRADALL XL SERIES CRAWLER
UNDERCARRIAGE.
Torque wrenches capable of achieving rated fastener values, wrenches for metric bolts and English S.A.E. bolts
must be available.
Large and small calipers, straight edges, steel measuring tape and a depth gauge are required for component
wear measurement.
Miscellaneous tools such as come-a-long, large C clamps, etc. may also be required for some repairs.
A grease fun and other tools GRADALL determines unique and necessary for good maintenance are furnished
in the tool kit supplied with each machine.
Form No. 29635 3/97
31
MAINTENANCE MANUAL
Electric Drives
and Controls
Hydraulics
Linear Motion and

Assembly Technologies
Pneumatics
Verstellpumpe A11VO/A11VLO
Variable Pump A11VO/A11VLO
Baureihe / Series 11
NG / Size 190 260
Reparaturanleitung / Repair Manual

Baugruppen / Assembly Groups
Service
RDE 92500-21-R/07.07
R1
2/32
Bosch Rexroth AG
Reparaturanleitung/Repair Manual A11VO / A11VLO
RDE 92500-21-R/07.07
Vermeidung von Gefahren
Avoiding Dangers
Fr einen sicheren Betrieb und um Schden bei der Reparatur

zu vermeiden, lesen Sie diese Reparaturanleitung sorgfltig
und aufmerksam durch!
To ensure safe operations and avoid damages during repairs,

read this repair manual carefully and attentively.
Fr Personen- oder Maschinenschden, die durch Nichtbeachtung dieser Reparaturanleitung entstehen, verfllt jegliche
Gewhrleistung der Bosch Rexroth AG.
Bosch Rexroth AG accepts no responsibility for personal

injuries or damages to the machine that arise from disregarding
this repair manual.
Zu dieser Anleitung
About this Manual
Diese Anleitung untersttzt Sie bei der Reparatur und der

Wiederinbetriebnahme von Rexroth A11VO/A11VLO Verstellpumpen Diese Anleitung umfasst die folgenden Kapitel:
This manual supports you in the repair, adjustment and recommissioning of Rexroth A11VO/A11VLO variable pumps. The
manual is structured as follows:
Sicherheit auf Seite 7
Safety on page 7
Hier erhalten Sie grundstzliche Hinweise zum sicheren

Umgang mit Verstellpumpen und zu deren Betrieb.
This chapter provides you with basic hints and tips regarding
working with and operating variable pumps.
Lesen Sie dieses Kapitel, bevor Sie anfangen zu arbeiten.
Read this chapter before you start working.
Produktbeschreibung auf Seite 11
Product Description on page 11
Hier erfahren Sie, wie Sie den Typ einer Verstellpumpe

feststellen. Ferner nden Sie hier eine bersicht ber die
Funktionsweise und Informationen zur bestimmungsgemen
Verwendung der Pumpe
This chapter explains how you identify the fvariable pump.

Additionally, it provides you an overview about how the
variable pump works and information regarding the correct
usage.
Lesen Sie dieses Kapitel, um Ihr Grundwissen ber Verstellpumpen aufzufrischen.
Read this chapter to refresh your knowledge of the variable

pumps.
Austausch von Baugruppen auf Seite 15

Rexroth stellt verschieden Reparaturstze zur Verfgung.
Dieses Kapitel erklrt Ihnen, wie Sie Dichtungen und Baugruppen einer Verstellpumpe austauschen.
Funktionsprfungen auf Seite 25
Hier erfahren Sie, wie Sie die Funktion einer Rexroth
A11V(L)O Verstellpumpe mit LRDS-Regler berprfen
knnen.
Exchanging Subassemblies on page 15

Rexroth provides various replacement parts for repairs. This
section explains, how you exchange seals and components
of a variable pump.
Functional Checks on page 25
This chapter explains how you check the proper function of a
Rexroth A11V(L)O variable pump with LRDS regulator.
RDE 92500-21-R/07.07
1.1 Inhalt
Zu dieser Anleitung
Bosch Rexroth AG
3/32
1.1 Content
1.1 Inhalt
1.1 Content
1.2 Gltigkeitsbereich dieser Anleitung
1.2 Validity of this Manual
1.3 Wichtige Unterlagen
1.3 Important Documents
1.4 Gefahrenkennzeichnungen und Piktogramme
1.4 Danger Labels and Pictograms
2.1 Basic Safety Information
Sicherheit
2.1 Grundlegende Sicherheitshinweise
About this Manual
Safety
2.2 Anforderungen an das Personal
10
2.2 Requirements on the Personnel
10
11
11
3.1 Typschild
11
3.1 Name Plate
11
3.2 Funktionsbeschreibung
11
3.2 Functional Description
11
3.3 Technische Daten
13
3.3 Technical Data
13
15
15
4.1 Triebwelle abdichten
16
4.1 Sealing the Drive Shaft
16
4.2 Reglergehuse abdichten
19
4.2 Sealing the Control Unit Housing
19
4.3 Dichtungen austauschen
22
4.3 Replacing Seals
22
25
25
5.1 Vorbereitungen
25
5.1 Preparations
25
5.2 Prfung des Load-Sensing Reglers (S)
26
5.2 Checking the Load-Sensing Control (S)
26
5.3 Prfung des Leistungsreglers (LR)
27
5.3 Checking the Power Control (LR)
27
5.4 Prfung des Druckreglers (D)
29
5.4 Checking the Pressure Control (D)
29
Produktbeschreibung
Austausch externer Baugruppen
Funktionsprfungen
Product Description
Exchanging External Assembly Groups
Functional Checks
4/32
Bosch Rexroth AG
1.2
Gltigkeitsbereich dieser
Anleitung
1.2
RDE 92500-21-R/07.07
Validity of this Manual
Diese Reparaturanleitung gilt fr die Verstellpumpen A11VO/

A11VLO der Bosch Rexroth AG. Informationen zu zugelassenen Druckssigkeiten entnehmen Sie den Angaben des
Anlagenherstellers.
This manual is valid for the Bosch Rexroth variable pumps

A11VO/A11VLO. Refer to the system manufacturer for information about the allowed hydraulic uids.
Diese Reparaturanleitung richtet sich an folgende Zielgruppen:
This repair manual is directed at:
Anlagenbetreiber
the system operator
autorisierte Fachbetriebe bzw. Hndler
authorized dealers
Anlagenhersteller
the system manufacturer
Fr den Anlagenhersteller sind zustzlich auch die jeweilige

Einbauzeichnung, das technische Datenblatt, die Betriebsanleitung und die Auftragsbesttigung der Bosch Rexroth AG
verbindlich.
For the system manufacturer, the installation drawing, the

catalog sheet, the manual, and the conrmation of order from
the Bosch Rexroth AG are also obligatory.
RDE 92500-21-R/07.07
1.3
Wichtige Unterlagen
1.3
Bosch Rexroth AG
5/32
Important Documents
Bevor Sie mit den in dieser Anleitung beschriebenen Arbeiten

anfangen, stellen Sie sicher, dass Sie folgende Unterlagen
griffbereit haben:
Before you start any of the procedures described in this manual, make sure you have the following documents ready to hand:
Auftragsbesttigung
Conrmation of Order
Die Auftragsbesttigung enthlt die voreingestellten technischen Daten. Die Verstellpumpe darf nur unter den in der
Auftragsbesttigung angegebenen Werten und Bedingungen betrieben werden.
Einbauzeichnung
Die Einbauzeichnung der Verstellpumpe enthlt die Auenabmessungen, smtliche Anschlsse und den Schaltplan.
Technisches Datenblatt
Die technischen Datenbltter RD 92500 enthalten u. a. die
zulssigen technischen Daten fr die Verstellpumpen.
Gesamtschaltplan der Maschine bzw. Anlage
Der Hydraulikschaltplan und der elektrische Schaltplan der
Maschine bzw. Anlage enthalten die Informationen zu den
hydraulischen bzw. elektrischen Anschlssen. Diese Daten
brauchen Sie, um mit der Verstellpumpe als Teil der Maschine bzw. Anlage zu arbeiten. Die Unterlagen erhalten Sie vom
Maschinen- bzw. Anlagenhersteller.
RD 90300-B: Allgemeine Betriebsanleitung fr Verstellpumpen
Die allgemeine Betriebsanleitung untersttzt Sie bei Installation, Inbetriebnahme und Betrieb von Rexroth-Verstellpumpen.
Produktspezische Betriebsanleitung
Die produktspezische Betriebsanleitung enthlt spezielle,
fr die Verstellpumpe gltige Informationen. Informieren Sie
sich bei Rexroth, ob es zu Ihrer Verstellpumpe eine produktspezische Betriebsanleitung gibt.
The conrmation of order contains the values set during the

commissioning by Rexroth. The variable pump may only be
operated with the values and conditions specied in the
conrmation of order.
Installation Drawing
The installation drawing of the variable pump contains the
sizes, all connections and the wiring diagram.
Technical Data Sheet
The technical data sheets RE 92500 contain the maximum
allowed technical data for the variable pumps and further
information.
Hydraulic Diagram / Wiring Diagram
The hydraulic diagram and the wiring diagram of the unit or
system contain the information related to the hydraulic or
electric connections. You need this data to work with the
axial piston as part of the unit or system. You can get this
information from the unit or system manufacturer.
RE 90300-B: General Manual for Variable Pumps

The general manual supports you during the installation,
initiation, and operation of Rexroth variable pumps.
Product Specic Manual
The product-specic manual contains specic information
designed for the variable pump. Get in touch with Rexroth to
nd out if there is any product-specic information on your
variable pump.
Folgende Rexroth-Druckschriften geben Ihnen weitere Informationen zu Installation und Betrieb der Verstellpumpe:
The following Rexroth publications provide additional information to the installation and operation of variable pumps:
RD 90220: Druckssigkeiten auf Minerallbasis
RE 90220: Mineral-oil Based Pressure Fluids
Diese Druckschrift beschreibt die Anforderungen an eine

Druckssigkeit auf Minerallbasis fr den Betrieb in Rexroth-Verstellpumpen und untersttzt Sie bei der Wahl einer
Druckssigkeit fr Ihre Anlage.
RD 90221: Umweltfreundliche Druckssigkeiten HEES,
HEPG, HETG fr Verstellpumpen
Diese Druckschrift beschreibt die Anforderungen an eine
umweltfreundliche Druckssigkeit fr den Betrieb mit Rexroth-Verstellpumpen und untersttzt Sie bei der Wahl einer
Druckssigkeit fr Ihre Anlage.
RD 90223: Verstellpumpen fr den Betrieb mit HFDruckssigkeiten
Diese Druckschrift enthlt zustzliche Informationen zum Einsatz von Rexroth-Verstellpumpen mit HF-Druckssigkeiten.
RD 90300-03-B: Hinweise zum Einsatz von hydraulischen Antrieben bei tiefen Temperaturen
Diese Druckschrift enthlt zustzliche Informationen zum
Einsatz von Rexroth-Verstellpumpen bei tiefen Temperaturen.
This publication describes the requirements on a hydraulic

uid based on mineral oil for operation in an variable pump
and supports you in the selection of a hydraulic uid for your
system.
RE 90221: Environmentally Acceptable Hydraulic Fluids
HEES, HEPG, HETG for Variable Pumps
This publication describes the demands on environmentally
compatible, readily biodegradeable hydraulic uids HETG,
HEPG, HEES that can be used in Rexroth variable pumps
and supports you by the selection of a hydraulic uid for your
system.
RE 90223: Variable Pumps for Use with HF Fluids
This publication provides additional information for the use of
Rexroth variable pumps with HF hydraulic uids.
RE 90300-03-B: Instructions on the Use of Hydrostatic
Drives at Low Temperatures
This publication provides additional information for the use of
Rexroth variable pumps at low temperatures.
6/32
Bosch Rexroth AG
1.4
Gefahrenkennzeichnungen
und Piktogramme
Diese Anleitung unterscheidet zwischen Kategorien von Gefahren gem ISO Guide 37:
! GEFAHR
Weist auf hohes Risiko und die Gefahr von Tod oder schweren Verletzungen hin.
! WARNUNG
Weist auf mittleres Risiko und die Gefahr von Verletzungen
und schweren Sachschden hin.
! VORSICHT
Weist auf geringes Risiko und Sachschden hin.
Hinweis
Kennzeichnet Informationen, die zum besseren Verstndnis
der Maschinenablufe beitragen oder weist auf einen besonderen bzw. wichtigen Sachverhalt hin.
Tipp
Kennzeichnet Informationen, die zum efzienteren Arbeiten
beitragen.
1.4
RDE 92500-21-R/07.07
Danger Labels and Pictograms
This manual differentiates between the following categories of

hazards, according to ISO Guide 37:
! DANGER
Indicates high risk, mortal danger and serious injuries.
! WARNING
Indicates middle risk, injuries or serious material damage.
! CAUTION
Indicates low risk or material damage.
Note
Indicates information that contributes to a better understanding of the machine processes or indicates important information.
Tip
Indicates information that contributes to more efcient work.
RDE 92500-21-R/07.07
Sicherheit
Bosch Rexroth AG
7/32
Safety
Lesen Sie dieses Kapitel sorgfltig durch, bevor Sie mit Arbeiten an der Verstellpumpe beginnen.
Read through this chapter carefully before you start any work
on the variable pump.
Die Rexroth-Verstellpumpen sind im Sinne der Maschinenrichtlinie 98/37/EG Komponenten, die zum Einbau in eine Anlage
bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung beziehen sich nur auf die Verstellpumpe. Beachten Sie zustzlich
die Sicherheitsrichtlinien des Anlagenherstellers.
The Rexroth variable pumps are in the sense of the machine

guideline 98/37/EG components of a system. The safety guidelines in this manual only cover the variable pump. You must
additionally follow the system manufacturers safety guidelines.
Informieren Sie sich an Hand der allgemeinen Betriebsanleitung fr Verstellpumpen ber die bestimmungsgeme
Verwendung und die Sorgfaltspicht des Betreibers und
Bedieners.
Read the general manual for variable pump units to get more
information on the designated use and the operators obligation to exercise diligence.
2.1
2.1
Grundlegende
Sicherheitshinweise
Befolgen Sie die folgenden Sicherheitshinweise und die des

Anlagenherstellers genau, um Verletzungen und Gesundheitsschden sowie Sach- und Umweltschden auszuschlieen.
! GEFAHR
Basic Safety Information
Pay attention to the following safety information and that of the

system manufacturer to eliminate injuries and health damages
as well as damages to material or the environment.
! DANGER
Lebensgefahr
Danger to life
Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen

stellt eine Gefahr fr Leib und Leben dar.
Working on systems that have not been shut down completely

is life-threatening.
Die in diesem Dokument beschriebenen Arbeiten drfen nur

an stillgelegten Maschinen bzw. Anlagen vorgenommen
werden. Bevor Sie mit den Arbeiten beginnen:
The work described in this document must only be carried out

on a shut down system. Before you start any of the tasks:
Stellen Sie sicher, dass der Antriebsmotor nicht eingeschaltet werden kann.
Make sure that the motor cannot be switched on.
Stellen Sie sicher, dass smtliche kraftbertragenden Komponenten und Anschlsse (elektrisch, pneumatisch, hydraulisch) gem den Herstellerangaben ausgeschaltet sind und
nicht eingeschaltet werden knnen. Falls mglich, entfernen
Sie die Hauptsicherung der Maschine bzw. Anlage.
Make sure that all components and connections that carry

energy (electrical, pneumatic, hydraulic) have been shut
down according to the manufacturers instructions and
cannot be switched on. If possible, remove the main fuse.
Stellen Sie sicher, dass die Maschine bzw. Anlage komplett

hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den
Angaben des Maschinen- bzw. Anlagenherstellers.
Make sure that the system is completely unpressurized.

Follow the instructions of the system manufacturer.
! WARNUNG
! WARNING
Verletzungsgefahr
Danger of injury
Um Verletzungen zu vermeiden, beachten Sie bitte folgende

Empfehlungen betreffend Sicherheitskleidung:
To avoid injuries, pay attention to the following recommendations regarding safety clothing:
Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicherheitsschuhe mit Stahlkappen.
When working on the system, wear steel-toed safety shoes.
Tragen Sie bei Arbeiten mit gefhrlichen Stoffen (beispielsweise Druckssigkeiten) Schutzhandschuhe und Schutzbrille.
When working with dangerous substances (for example,

certain hydraulic uids), wear protective gloves and protective glasses.
8/32
Bosch Rexroth AG
! GEFAHR
RDE 92500-21-R/07.07
! DANGER
Vergiftungs- und Verletzungsgefahr
Danger of poisoning or injury
Der Kontakt mit Druckssigkeiten ruft Gesundheitsschden

hervor (z.B. Augenverletzungen, Haut- und Gewebeschdigungen, Vergiftungen beim Einatmen).
Contact with hydraulic uids can cause health damage (e. g.

eye injuries, skin and tissue damage, poisoning due to inhalation).
berprfen Sie vor jeder Inbetriebnahme die Leitungen auf

Verschlei bzw. Beschdigungen.
Always check the hydraulic lines for wear and damage prior
to putting the unit into operation.
Tragen Sie dabei Schutzhandschuhe und Schutzbrille.
When checking the lines, wear protective gloves and safety

glasses.
Wenn dennoch Druckssigkeit in die Augen gelangt oder

in die Haut eindringt, konsultieren Sie unmittelbar einen
Arzt.
Should pressure uid come into contact with your eyes or

skin: Get medical help immediately!
Beachten Sie beim Umgang mit Druckssigkeiten unbedingt die Sicherheitsangaben des Druckssigkeitsherstellers.
When handling hydraulic uids, pay attention to the hydraulic uid manufacturers safety instructions.
! WARNUNG
! WARNING
Verbrennungsgefahr
Danger of burns
Die Verstellpumpe erwrmt sich whrend des Betriebs. Auch

die Magnete an der Verstellpumpe werden im laufenden
Betrieb hei. Finger und Hnde knnen bei Berhrung der
Verstellpumpe oder der Magnete schwere Brandverletzungen
erleiden.
The variable pump heats up during operation. The units

solenoids get hot during operation. Fingers and hands can be
badly burned when touching the variable pump or solenoids.
Lassen Sie die Verstellpumpe vor jedem Kontakt abkhlen.
Let the variable pump cool down prior to any contact.
Schtzen Sie sich mit hitzebestndigen Handschuhen und

Schutzkleidung.
Protect yourself from burns by wearing safety gloves and

protective clothing.
! GEFAHR
! DANGER
Vergiftungs- und Verletzungsgefahr
Danger of poisoning and injuries
Beim Suchen nach Leckstellen kann entweichende Druckssigkeit in die Haut eindringen und schwerste Vergiftungen und
Verletzungen hervorrufen.
When looking for leaks, escaping hydraulic uid can break

into the skin and cause serious poisoning and injuries.
Suchen Sie nur bei abgestellter und druckloser Maschine

nach Leckstellen.
Look only for leaks, if the variable pump unit is shut down
and unpressurized.
! WARNUNG
! WARNING
Verletzungs- und Beschdigungsgefahr
Danger of injuries or damage
Durch falsch angeschlossene Komponenten knnen erhebliche Fehlfunktionen entstehen.
Incorrectly connected components can considerably impair

the functionality of a hydraulic system.
Achten Sie auf korrekte Verrohrung gem Schaltplan.
Make sure that the hydraulic lines are connected properly

according to the wiring diagram.
Fhren Sie komponentenorientierte Funktionstests durch.
Check the correct functioning of all components.
RDE 92500-21-R/07.07
! GEFAHR
Bosch Rexroth AG
9/32
! DANGER
Feuergefahr
Danger of re
Hydraulische Druckssigkeit ist brennbar.
Hydraulic uid is inammable.
Halten Sie offenes Feuer und Zndquellen von der Verstellpumpe fern.
Keep open res and ignition sources away from the variable
pump.
! WARNUNG
! WARNING
Gehrschden
Danger of hearing damage
Die Geruschemission von Verstellpumpen ist u.a. von Drehzahl, Betriebsdruck und Einbauverhltnissen abhngig. Es ist
damit zu rechnen, dass der Schalldruckpegel bei normalen
Einsatzbedingungen ber 70 dBA steigt. Dies kann zu Gehrschden fhren.
The noise emission produced by variable pump units depends

on speed, operating pressure, and installation. During normal
application conditions, over 70 dBA can be anticipated. This
can lead to hearing damage.
Schtzen Sie sich stets mit Gehrschutz bei Arbeiten in der

Nhe der Verstellpumpe whrend des laufenden Betriebs.
Always wear hearing protection when working in the vicinity

of the variable pump during operation.
! WARNUNG
! WARNING
Umweltschden
Risk of damage to the environment
Druckssigkeiten sind wassergefhrdende Flssigkeiten.

Das Austreten von Druckssigkeiten kann zu Grundwasservergiftung und Bodenverseuchung fhren.
Hydraulic uid is hazardous to waters.

Hydraulic uid leakage leads to contamination of the ground
and ground water.
Bringen Sie unter der Verstellpumpe eine Auffangwanne an.
A basin for catching any hydraulic uid must be placed

under the variable pump.
Beseitigen Sie Leckstellen unverzglich.
Leaks must be cleaned up immediately.
Es sind stets die nationalen Gesetze und Vorschriften zu

beachten. In Deutschland sind hydraulische Maschinen bzw.
Anlagen Anlagen zum Umgang mit wassergefhrdenden
Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG).
Beachten Sie in diesem Zusammenhang besonders 1 und
19 WHG (19g, 19i, 19l).
Pay always attention to any national regulations and norms.

In Europe, hydraulic systems are considered Systems
using water-threatening substances in the sense of the
Water Management Law (WHG).Therefore, pay special
attention to 1 and 19 WHG (19g, 19i, 19l).
Weitere Informationen nden Sie in den RexrothDruckschriften Druckssigkeiten auf Minerallbasis,

RD 90 220, Umweltschonende, biologisch schnell abbaubare Druckssigkeiten HEPG, HEES fr Axialkolbenmaschinen, RD 90 221-1 und Axialkolbenmaschinen fr den
Betrieb mit HF-Druckssigkeiten, RD 90 223.
Further information is available in the Rexroth publications

Mineral-oil based hydraulic uids, RE 90 220. Environmentally acceptable, rapid biologically degradable hydraulic
uids HEPG, HEES for axial piston units, RE 90 221-1
and Axial piston units for operation with HF hydraulic uids,
RE 90 223.
10/32
Bosch Rexroth AG
2.2
Anforderungen an das Personal
2.2
RDE 92500-21-R/07.07
Requirements on the Personnel
Diese Reparaturanleitung richtet sich an Fachkrfte mit

Hydraulik-Fachwissen, die an einer Service-Schulung bei
Rexroth teilgenommen haben.
This repair manual is directed at qualied personnel with

specialized hydraulics know-how who have taken part at a
service training at Rexroth.
Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung

und Erfahrung ausreichende Kenntnisse hat, sowie mit den
einschlgigen Bestimmungen so weit vertraut ist, dass er
Qualied personnel is dened as persons who have sufcient

knowledge on the basis of specialized training and experience,
and are familiar with the relevant regulations, so that they are
able to
die ihm bertragenenen Arbeiten beurteilen kann,
judge the delegated tasks,
mgliche Gefahren erkennen kann,
recognize possible dangers,
die notwendigen Manahmen zur Beseitigung von Gefahren

ergreifen kann,
take the necessary measures for the elimination of dangers,
Kenntnisse ber die mglichen Gesundheitsgefahren von

Druckssigkeiten hat
know the possible health risks from hydraulic uids,
und die erforderlichen Reparatur- und Montagekenntnisse

hat.
and have the required repair and installation know-how.
Hydraulik-Fachwissen bedeutet, das Personal muss
Specialized hydraulics know-how means that the personnel

must:
in der Lage sein, die Hydraulikplne zu lesen und vollstndig

zu verstehen,
be able to read and completely understand hydraulic plans
insbesondere die Zusammenhnge bezglich der eingebauten Sicherheitseinrichtungen vollstndig verstehen
especially understand completely the coherences regarding

the installed safety equipment
und Kenntnisse ber Funktion und Aufbau von hydraulischen

Bauteilen haben.
be familiar with the function and structure of hydraulic components.
RDE 92500-21-R/07.07
Bosch Rexroth AG
Produktbeschreibung
11/32
Product Description
Dieses Kapitel gibt Ihnen einen allgemeinen berblick ber die

Funktionalitt der Rexroth A11VO/A11VLO Verstellpumpen.
This chapter provides a general overview of the functionality of

the A11VO/A11VLO variable displacement pumps.
Machen Sie sich mit den Inhalten dieses Kapitels vertraut,

bevor Sie mit Arbeiten an einer Verstellpumpe beginnen.
You should be familiar with the contents of this chapter before

starting any work on the variable displacement pump.
3.1
3.1
Typschild
Die Verstellpumpe ist am Typschild zu identizieren (Beispiel):
Name Plate
The variable displacement pump can be identied on its type

plate (example):
Rexroth
D-89275 Elchingen
2
3
TYP: A11VLO190LRDS/10R-NZD12N00
MNR: R90XXXXXXX
4
5
SN:
FD:
7202
12345678
07W09
Rotation:
n = XXXX min
-1
p = XXX kW
7
8
9
10
Made in Germany
Folgende Informationen nden Sie auf dem Typschild:
The following information can be found on the type plate:
1 Hersteller
1 Manufacturer
2 Typschlssel
2 Ordering code
3 Materialnummer der Axialkolbenmaschine
3 Material number of the axial piston unit
4 Seriennummer
4 Serial number
5 Fertigungsdatum
5 Date of manufacturing
6 Drehzahl
6 Speed
7 interne Werksbezeichnung
7 Internal manufacturing code
8 Drehrichtung (bei Blick auf die Welle; hier: im Uhrzeigersinn)
8 Direction of rotation (when facing the shaft; here: clockwise)
9 Vorgesehener Platz fr Prfstempel
9 Designated space for certication stamp
10 Leistung
10 Power
Stellen Sie sicher, dass Typ und Nenngre der zu reparierenden Verstellpumpe mit dieser Anleitung bereinstimmen.
Ensure that the variable displacement pump to be repaired is

of the type and size covered by this manual.
3.2
3.2
Funktionsbeschreibung
Functional Description
Damit Sie in der Lage sind, Probleme an der Verstellpumpe

zu identizieren und gezielt Reparaturen durchzufhren, sind
Kenntnisse der Funktionsweise und des Aufbaus erforderlich.
Dieser Abschnitt gibt Ihnen eine grobe bersicht.
To make sure that you are able to identify problems with a

variable displacement pump and to carry out specic repairs,
familiarity with how the unit functions and its assembly are
required. This section provides you with a rough overview.
Die A11VO/A11VLO Verstellpumpen sind Axialkolben-Verstellpumpe in Schrgscheibenbauart fr hydrostatische Antriebe

im offenen Kreislauf. Der Volumenstrom ist proportional zu der
Antriebsdrehzahl und dem Verdrngungsvolumen. Durch die
Verstellung der Schrgscheibe ist eine stufenlose Volumenstromnderung mglich.
The variable displacement axial piston pumps type A11VO/

A11VLO in swashplate design are designed for open circuit
hydrostatic drives. The ow is proportional to the input drive
speed and displacement. By adjusting the swashplate, it is
possible to innitely vary the ow.
A11VLO Pumpen haben einen eingebauten Impeller (Ladepumpe). Das ist eine Kreiselpumpe, die es erlaubt, die Pumpen mit
hheren Drehzahlen zu betreiben.
A11VLO pumps have a built-in impeller. This is a turbo pump

that makes it possible to increase the rotational speed for
driving the pumps.
12/32
Bosch Rexroth AG
RDE 92500-21-R/07.07
Schnittzeichnungen
Sectional Drawings
Die folgenden Schnittzeichnungen zeigen den Aufbau der

A11VO/A11VLO Verstellpumpe.
The following drawings show the design of the A11VO/

A11VLO variable displacement pump.
A11VLO 190, 260 LRDS
Qmin Stop
Triebwerk /
Rotary Unit
Regler /
Control Unit
Antriebswelle /
Drive Shaft
Verschlussring mit Wellendichtring /

Cover Ring with Shaft Seal
Ladepumpe / Impeller
Qmax Stop
Qmin Stop / Qmax Stop: Anschlag fr minimalen/maximalen

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

angle.
Reglerbeispiele / Control Unit Examples
LRDS
DRS
LRDH
RDE 92500-21-R/07.07
Bosch Rexroth AG
13/32
EP
LR:
3.3
Leistungsregler
Power Control
D, DR: Druckregler
Pressure Control
S:
Load-Sensing
Load-Sensing Control
EP:
Elektrische Verstellung
Electrical Control
HD:
Hydraulische Verstellung
Hydraulic Control
Technische Daten
Die technischen Daten der Verstellpumpe nden Sie in der

Auftragbesttigung. Ergnzend dazu ist das jeweilige technische Datenblatt. Fr die A11VO/A11VLO Verstellpumpe gilt
das technische Datenblatt RD 92500.
3.3
Technical Data
You can nd the technical data for the variable displacement

pump in the Conrmation of Order. This is supplemented by
the units data sheet. For the A11VO/A11VLO variable displacement pump, the valid data sheet is RE 92500.
14/32
Bosch Rexroth AG
RDE 92500-21-R/07.07
RDE 92500-21-R/07.07
Austausch externer
Baugruppen
Bosch Rexroth AG
15/32
Exchanging External
Assembly Groups
Dieses Kapitel beschreibt den Austausch von Baugruppen und

Dichtungen der Verstellpumpen A11VO/A11VLO.
This chapter describes the replacement of the externally accessible assembly groups and sealings of the variable pumps
A11VO/A11VLO.
Der Austausch von Dichtungen folgender Baugruppen wird

beschrieben:
The exchange of sealings of the following assembly groups is

described:
Triebwelle
Drive shaft
Regler
Control unit
Dichtmuttern
Seal Locks
! WARNUNG
! WARNING
Gefahr von Verschlei und Funktionsstrungen
Danger of wear and malfunction
Die Sauberkeit der Druckssigkeit und die Lebensdauer der

Hydraulikanlage stehen in unmittelbarem Zusammenhang.
Verschmutzung der Druckssigkeit fhrt zu Verschlei und
Funktionsstrungen. Insbesondere harte Fremdkrper in den
Hydraulikleitungen, wie z.B. Schweiperlen und Metallspne,
beschdigen die Axialkolbenmaschine.
The durability of the hydraulic unit depends to a great extent

on how clean the unit is kept. Dirt in the hydraulic uid can
lead to malfunctions. Especially hard foreign matter in the hydraulic lines, for example, welding beads and metal cuttings,
will denitely damage the axial piston unit.
Beachten Sie daher unbedingt folgende Hinweise:
Therefore you should observe the following instructions:
Achten Sie auf uerste Sauberkeit. Die Axialkolbenmaschine muss schmutzfrei eingebaut werden. Verunreinigungen
in der Druckssigkeit knnen die Funktion und Lebensdauer der Axialkolbenmaschine erheblich beeintrchtigen.
Make sure everything is kept extremely clean. The axial piston unit must be installed in a dirt-free environment. Contamination of the hydraulic uid can lead to considerable wear
and malfunctions of the axial piston unit.
Achten Sie besonders bei der Installation darauf, dass

Anschlsse, Hydraulikleitungen und Anbauteile ( z.B. Messgerte) sauber sind. Reinigen Sie diese grndlich, bevor
Sie Anschlsse ffnen. Stellen Sie sicher, dass auch beim
nachfolgenden Verschlieen der Anschlsse keine Verunreinigungen eindringen.
Especially during the installation, you should make sure that

ports, hydraulic conduits, and mounting components (for
example, gauges) are clean. Clean these thoroughly before
you open connections. After that, when sealing the ports,
make sure that contaminating elements cannot enter the
system.
Verwenden Sie fr die Beseitigung von Schmiermitteln und

anderen starken Verschmutzungen geeignete ssige Reinigungsmittel. Es darf kein Reinigungsmittel in das Hydrauliksystem eindringen.
When removing grease and other dirt you should use appropriate liquid cleaning agents. Cleaning agents must not
enter the hydraulic system.
Verwenden Sie zur Reinigung keine Putzwolle oder fasernde Putzlappen.
Do not use cotton waste or rags which lose threads.
Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder

Kitt.
Never use hemp or putty as a sealant.
16/32
Bosch Rexroth AG
4.1
Triebwelle abdichten
4.1
RDE 92500-21-R/07.07
Sealing the Drive Shaft
Dieser Abschnitt erklrt, wie Sie die Triebwelle abdichten.
This section explains how you seal the drive shaft.
Bentigtes Sonderwerkzeug:
Required Special Tools:
Montagebchse
Mounting sleeve
Die Materialnummern sind je nach Pumpenmodell verschieden:
The material number depends on the pump model:
A11VO/A11VLO
A11VO/A11VLO
NG 190:
Mat. Nr. R90450647
Size 190:
Mat. no. R90450647
NG 260:
Mat. Nr. R90450941
Size 260:
Mat. no. R90450941
e
c
d
b
a
a:
Sicherungsring
Circlip
b:
Verschlussring
Cover Ring
c:
Wellendichtring
Shaft Seal
d:
O-Ring
O-ring
e:
Triebwelle
Drive Shaft
Um die Triebwelle abzudichten:
To seal the drive shaft:
1 Kleben Sie die Triebwelle (e) ab, um Beschdigungen bei

der Montage des neuen Wellendichtrings zu vermeiden.
1 Mask the drive shaft (e) for damage protection while replacing the shaft seal.
e
RDE 92500-21-R/07.07
Bosch Rexroth AG
2 Entfernen Sie den Sicherungsring (a).
17/32
2 Remove the circlip (a).

a
3 Drcken Sie den Verschlussring (b) ab.

Damit entfernen Sie auch den Wellendichtring, der in den
Verschlussring eingepresst ist
3 Press off the cover ring (b).

This action removes also the shaft seal that is pressed into
the cover ring.
b
4 Entfernen Sie den Wellendichtring (c) aus dem Verschlussring (b) sowie den O-Ring (d) aus dem Gehuse.
Kontrollieren Sie den Verschlussring (b), die Triebwelle (e)
und das Gehuse (f) auf Verschlei und Verunreinigungen.
4 Remove the shaft seal (c) from the cover ring (b) and the
o-ring (d) from the housing.
Check the cover ring (b), the drive shaft (e), and the housing
(f) for wear and dirt.
e
f
d
b
c
18/32
Bosch Rexroth AG
5 Pressen Sie den Wellendichtring (c) mit Hilfe der passenden

Montagebchse (g) (Sonderwerkzeug) lagerichtig in den
Verschlussring ein.
RDE 92500-21-R/07.07
5 Using the suitable mounting bush (g) (special tool), press in

the shaft seal (c) until it is correctly orientated in the cover
ring.
g
g
c
Bei tiefer Laufrille legen Sie eine Scheibe auf den Wellendichtring.
If the shaft is deeply grooved, insert a shim behind the shaft

seal.
6 Fetten Sie den neuen Wellendichtring zwischen Dicht- und

Staublippe leicht ein, um Trockenlauf zu vermeiden.
6 Grease the new shaft seal between the seal and dust lips to
avoid a dry run.
7 Fetten Sie den neuen O-Ring (d) leicht ein und legen Sie ihn
in das Gehuse (f) ein. Prfen Sie, ob der O-Ring bndig
anliegt.
7 Grease the the new o-ring (d) slightly and insert it into the
housing (f). Ensure, that it is correctly placed.
d
f
8 Setzen Sie den Verschlussring mit dem Wellendichtring in

das Gehuse ein.
8 Insert the cover ring with the shaft seal into the housing.
9 Fhren Sie den Sicherungsring (a) so in das Gehuse (f) ein,

dass er in die dafr vorgesehene Nut des Verschlussrings
einrastet.
Kontrollieren Sie den Sitz des Sicherungsrings in der Nut.
9 Place the safety ring (a) into the housing (f) so that it locks
into place in the respective slot of the cover ring.
Check to ensure that the circlip is correctly located within
the groove.
a
f
10 Entfernen Sie die Abklebung der Triebwelle.
10 Remove the mask from the drive shaft.
RDE 92500-21-R/07.07
4.2
Bosch Rexroth AG
Reglergehuse abdichten
4.2
Das Reglergehuse wird mit vier O-Ringen gegen die Anschlussplatte abgedichtet.
19/32
Sealing the Control Unit Housing
Four o-rings are used to seal the regulator housing from the
port plate.
a:
Anschlussplatte
Port Plate
b:
Regler
Control Unit
c:
O-Ringe
O-rings
d:
Messkolben mit Winkelhebel
Measuring Piston with angled Lever
20/32
Bosch Rexroth AG
Regler, z. B. LRDS
RDE 92500-21-R/07.07
Control Unit Example, LRDS
S
D
LR
LR:
Leistungsregler
Power control
D:
Druckregler
Constant pressure control
S:
Load-sensing Regler
Load-sensing valve
Hinweis
Einstellschrauben nicht verndern. Falls erforderlich, Gewindehlse komplett mit Einstellschrauben ausbauen.
! VORSICHT
Vor dem Abschrauben eines Reglers mit Messfeder (z. B.
LRDH, EP):
Zuerst Steuerbuchse mit Messfeder ausbauen, dann Reglergehuse abbauen!.
Note
Do not change the position of adjustment screws. If necessary, remove the complete set of threaded bush with adjustment
screws.
! CAUTION
Before removing a control unit with measuring spring (for
example LRDH, EP):
First remove the control bush with the measuring spring, then
remove the regulator housing!
RDE 92500-21-R/07.07
Bosch Rexroth AG
Beispiel fr einen Regler mit Messfeder
21/32
Example of a Control Unit with Measuring Spring
EP
Ausbauen /
Remove
Um den Regler abzudichten:
To seal the control unit:
1 Entfernen Sie die fnf Befestigungsschrauben.
1 Remove the ve xing screws.
2 Drcken Sie den Regler ab.
2 Press off the control unit.
! VORSICHT
! CAUTION
Dichtche nicht beschdigen!
Make sure that the sealing surface is not damaged!
3 Legen Sie vier neue O-Ringe in die Anschlussplatte ein.
3 Insert four new o-rings into the grooves of the port plate.
22/32
Bosch Rexroth AG
4 Achten Sie vor dem Aufsetzen des Reglers auf die korrekte
Positionierung von Messkolben und Winkelhebel (d).
RDE 92500-21-R/07.07
4 Before mounting the regulator ensure that the measuring

piston and angled lever (d) are correctly positioned.
5 Ziehen Sie die fnf Befestigungsschrauben an.
5 Insert and tighten the ve xing screws
4.3
4.3
Dichtungen austauschen
Replacing Seals
Dieser Abschnitt erklrt, wie Sie die Dichtmuttern ersetzen.
This section explains how you replace the seal nuts.
Bentigtes Sonderwerkzeug: Keines
Required special tools: None
Um eine Dichtmutter auszutauschen:
To replace a seal nut:
1 Messen und notieren Sie das Ma X fr die sptere Montage

der Dichtmutter (a).
1 Measure and write down the dimension X of the seal nut (a).
You need this for the subsequent assembly.
Entfernen Sie die Dichtmutter.
Remove the seal nut.
a
X
2 Schrauben Sie die neue Dichtmutter (a) ein. Blockieren Sie

die Stellschraube (b) whrend Sie die Dichtmutter festziehen.
Kontrollieren Sie das Ma X nach der Montage.
2 Screw in the new seal lock (a) manually. Block the adjusting
screw (b) while you tighten the seal nut.
Check the dimension X after assembly.
a
b
RDE 92500-21-R/07.07
Anziehdrehmomente fr Seal-Lock Dichtmuttern

(nach N 02.100)
Gewinde /
Thread
Bosch Rexroth AG
Tightening Torques for Seal-Lock Sealing Nuts

(according to N 02.100)
Anziehdrehmoment MA in Nm
Tightening torque MA in Nm
M6
10
M6 x 0,5
11
M8
22
M8 x 1
24
M10
40
M10 x 1
44
M12
69
M12 x 1,5
72
M14
110
M14 x 1,5
120
M16
170
M16 x 1,5
180
23/32
24/32
Bosch Rexroth AG
RDE 92500-21-R/07.07
RDE 92500-21-R/07.07
Bosch Rexroth AG
Funktionsprfungen
25/32
Functional Checks
Dieses Kapitel gibt Ihnen Beispiele, wie Sie die Funktion einer
Rexroth A11VO/A11VLO Verstellpumpe mit LRDS-Regler
berprfen knnen.
This chapter provides examples on how to check the proper

function of a Rexroth A11VO/A11VLO variable pump with
LRDS regulator.
5.1
5.1
Vorbereitungen
Preparations
1 Fordern Sie das Leistungsdiagramm bei Bosch Rexroth an.
1 Order the power curve diagram at Bosch Rexroth.
2 berprfen Sie die Drehrichtung.
2 Check the direction of rotation.
3 Bauen Sie die Pumpe ein, befestigen Sie sie, und befllen
Sie das Gehuse.
3 Install and x the pump. Fill the housing.
Anschlsse / Ports
A11VO/A11VLO 190 ... 260 LRDS
X
X
S
D
LR
M1
M:
Messstelle Arbeitsanschluss
Test port for pressure
M1 :
Messstelle Stellkammer
Test port for stroking cylinder
LR:
Leistungsregler
Power Control
D:
Druckabschneidung
Pressure Cut-off
S:
Load-Sensing-Regler
X:
Anschluss fr LS-Regler
Port for LS Control
G:
Anschluss fr Fremdstelldruck
Port for externally applied

control pressure
26/32
Bosch Rexroth AG
5.2
Prfung des Load-Sensing Reglers (S)
5.2
RDE 92500-21-R/07.07
Checking the Load-Sensing Control (S)
Einstellvorgang
Setting process
1 Auf Prftemperatur fahren
1 Heat up the system to test temperature
2 Antriebsdrehzahl einstellen
2 Set drive speed
3 Qmin Anschlag ausschrauben
3 Screw out Qmin stop
4 Verwenden Sie folgenden Testaufbau
4 Use the following test setup
Testaufbau
Test Setup
Messmotor-Volumenstrommessgert /
Measuring Motor
Belastungsventil /
Charge Valve
Messblende - Absperrhahn /
Measuring Throttle - Locking Tap
pHD2
pdiff
pHD1
Dreiwegehahn /
3-Way Tap
Anschlsse
Connections
Dreiwegehahn /
3-Way Tap
Messblende - Absperrhahn /
Measuring Throttle - Locking Tap
M A,
Druckregler / Constant Pressure Control

Load-Sensing-Regler /
Leistungsregler /
HP-Control
M1
RDE 92500-21-R/07.07
Bosch Rexroth AG
27/32
5 Messblende/Absperrhahn vorsichtig schlieen bis Qmax/2

(halber Volumenstrom).
Hochdruck 100 bar (pHD2) nach der Messblende (Belastungsventil) einstellen.
5 Carefully close the measuring throttle's locking tap up to

Qmax/2 (half ow).
Set high pressure 100 bar (pHD2) behind the measuring
throttle (charge valve).
6 pdiff am LS-Regler einstellen und kontern.
6 Set pdiff at the HP-control and jam the screw.
Zum Beispiel: pdiff = 18 bar:
For example: pdiff = 18 bar:
pHD2 = 100 bar
pHD2 = 100 bar
pHD1 = 118 bar
pHD1 = 118 bar
7 Dreiwegehahn in der X-Leitung vorsichtig schlieen.
7 Close the measuring throttle's locking tap entirely.
8 Qmin Schraube anlegen, 1/2 Umdrehung wieder herausdrehen und kontern.
8 Place Qmin screw, screw-out again 1/2 rotation and jam the
screw.
5.3
5.3
Prfung des Leistungsreglers (LR)
Checking the Power Control (LR)
Einstellvorgang
Setting process
1 Druckregler blockieren (eindrehen).
1 Block constant pressure control (screw-in).
2 Leistungsregler nach Leistungsdiagramm (LD) einstellen.
2 Set the power control as to HP diagram (power diagram).
3 Messblende, Absperrhahn ffnen.
3 At the measuring throttle, open the locking tap.
4 Frderstrom Qmax einstellen (Qmax-Schraube).
4 Set ow to Qmax (Qmax screw).
Beispiel 1
Example 1
Einstellung des Regelbeginns ber einen Punkt auf der Leistungskennlinie nach Druck und Volumen.
Setting the start of regulation at a point of the horse power

diagram (pressure/ow).
28/32
Bosch Rexroth AG
RDE 92500-21-R/07.07
Beispiel 2
Example 2
Einstellung des Regelbeginns. Druck (Stelldruck) an M1.
Setting the start of regulation, pressure (stroking pressure) at

M1.
Hinweis
Note
Diese Einstellung ist ungenau (Toleranz).
This setting is unprecise (Tolerance).
Beispiel:
Example:
Regelbeginn = 120 bar.
Begin of regulation = 120 bar.
Betriebsdruck langsam erhhen bis Manometer an

M = 120 bar anzeigt. Ddabei darf der Stelldruck an M1 ca. 1/3
vom Betriebsdruck, also etwa 40 bar betragen.
Slowly increase operation pressure up to pressure gauge at

M = 120 bar. The positioning pressure at M1 may be up to
approx. 1/3 of the operation pressure, i.e. approx. 40 bar.
Das ist der Regelbeginn.
This is the start of the regulation.
Zum Beispiel:
For example:
Druck an M = 120 bar
Pressure at M = 120 bar
Druck an M1 = 20 bar
Pressure at M1 = 20 bar
Regelbeginn zu spt, also Leistungsberschreitung
Start of regulation too late, i.e. Power excess.
Einstellschraube herausdrehen bis ca. 40 bar erreicht werden.
Unscrew setting screw until approx. 40 bar are reached.
M =120 bar
M1 =40 bar
RDE 92500-21-R/07.07
5.4
Prfung des Druckreglers (D)
5.4
Bosch Rexroth AG
29/32
Checking the Pressure Control (D)
Einstellung des Druckreglers mittels Belastungsventil nach

Leistungsdiagramm.
Setting with help of the charge valve the constant pressure

control as to HP diagram.
Beispiel: Druckreglereinstellung = 310 bar
Example: Setting of constant pressure control = 310 bar
1 Betriebsdruck mit Belastungsventil auf ca. 350 bar erhhen.
1 Increase operation pressure with help of charge valve to

approx. 350 bar.
2 Blockierten Druckregler vorsichtig herausdrehen bis 310 bar

erreicht werden.
2 Unscrew blocked constant pressure control carefully until

310 bar are reached.
3 Einstellschraube kontern.
3 Jam setting screw.
30/32
Bosch Rexroth AG
RDE 92500-21-R/07.07
RDE 92500-21-R/07.07
Bosch Rexroth AG
31/32
32/32
Bosch Rexroth AG
RDE 92500-21-R/07.07
Alle Rechte bei Bosch Rexroth AG, auch fr den Fall von Schutzrechtsanmeldungen.
Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Die angegebenen Daten dienen allein der Produktbeschreibung. Eine Aussage ber eine
bestimmte Beschaffenheit oder eine Eignung fr einen bestimmten Einsatzzweck kann
aus unseren Angaben nicht abgeleitet werden. Die Angaben entbinden den Verwender
nicht von eigenen Beurteilungen und Prfungen. Es ist zu beachten, dass unsere Produkte einem natrlichen Verschlei- und Alterungsprozess unterliegen.
nderungen vorbehalten.
Bosch Rexroth AG
Hydraulics
Produktsegment Axialkolbenmaschinen
Werk Elchingen
Glockeraustrae 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax
+49 (0) 73 08 72-74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
This document, as well as the data, specications and other information set forth in
it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to
third parties without its consent.
The data specied above only serve to describe the product. No statements concerning
a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment
and verication. It must be remembered that our products are subject to a natural process
of wear and aging.
Subject to change.
HY13-1512-004-M1/US
TorqmotorTM
Service Procedure
Effective:
March 2005
TC, TB, TE, TJ, TF,

TG, TH and TL Series
Low Speed, High Torque
Hydraulic TorqmotorsTM
HY13-1512-004-M1/USA
Torqmotor Service Procedure

TC,TB, TE, TJ, TF, TG, TH and TL Series
WARNING
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR
RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product and/or
system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application
and review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions and
applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection
of the products and systems and assuring that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to
change by Parker Hannifin Corporation and its subsidiaries at any time without notice.
Offer of Sale
The items described in this document are hereby offered for sale by Parker Hannifin Corporation, its subsidiaries or its authorized distributors.
This offer and its acceptance are governed by the provisions stated in the "Offer of Sale".
Copyright 2005, 2000, 1999, Parker Hannifin Corporation, All Rights Reserved
Parker Hannifin Corporation

Hydraulic Pump/Motor Division
Greeneville, TN 37745 US

HY13-1512-004-M1/USA
Table of Contents
Definitions ............................................................................................................................................................... 3
Design Features ................................................................................................................................................. 4 - 5
Introduction ............................................................................................................................................................. 7
Troubleshooting Guide ............................................................................................................................................. 8
Troubleshooting Checklist ....................................................................................................................................... 9
Tools and Material Required for Servicing .............................................................................................................. 10
Bolt Torque ............................................................................................................................................................ 11
Exploded Assembly View ................................................................................................................................. 12-13
TC Service Parts List Chart ............................................................................................................................. 14-15
TB Service Parts List Chart ............................................................................................................................. 16-17
TE Service Parts List Chart ............................................................................................................................. 18-19
TJ Service Parts List Chart ................................................................................................................................... 20
TF Service Parts List Chart ............................................................................................................................. 21-22
TG Service Parts List Chart ............................................................................................................................. 23-24
TH Service Parts List Chart ............................................................................................................................. 25-26
TL Service Parts List Chart ................................................................................................................................... 27
Disassembly & Inspection ............................................................................................................................... 28-35
Torqmotor Assembly ..................................................................................................................................... 36-45
Rotor Set Component Assembly Procedure (One Piece Stator) ............................................................................ 46
Rotor Set Component Assembly Procedure (Two Piece Stator) ........................................................................ 47-48
Final Checks ......................................................................................................................................................... 49
Hydraulic Fluids .................................................................................................................................................... 49
Filtration, Oil Temperature ..................................................................................................................................... 49
Tips for Maintaining the System ............................................................................................................................ 50
Offer of Sale ................................................................................................................................ Inside Back Cover
Definitions
NOTE:
CAUTION:
WARNING:
A NOTE provides key information to make a procedure easier or quicker to complete.

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


HY13-1512-004-M1/USA
Torqmotor Design Features
Torqmotor TB/TC Series features

include:
COUPLING SHAFT
HIGH PRESSURE SEAL
NEEDLE THRUST
BEARING
HOUSING
DRIVE LINK
12-TOOTH
SPLINES
DIRT & WATER SEAL

BUSHING
MATCHED ROTOR SET
MATCHED COMMUTATOR SET
COUPLING SHAFT
The roller vane rotor set design offers a

low-friction, wear compensation which
maximizes the useful performance life of the
motor.
Zero leak commutation valve provides
greater, more consistent volumetric
efficiency.
Design flexibility - TB offers the widest
selection of shaft options, displacements
and mounting flanges in the industry.
Patented 60-40 spline member arrangement transmits more torque with less weight.
Full flow lubrication maximizes cooling
and may provide up to 50% longer life than
motors not having this feature.
Higher pressure rating provide greater
torque than competitive brands.
Full interchangeability with other motors
which are designed according to industry
standards.
Compatible with most hydraulic systems
with regard to pressure, torque and speed.
A unique high-pressure shaft seal that
eliminates the need for case drains.
Up to 13 horsepower output.
Torqmotor TE Series features

include:
HIGH PRESSURE SEAL

NEEDLE THRUST BEARING
HOUSING
DRIVE LINK
12-TOOTH
SPLINES
DIRT & WATER SEAL
NEEDLE RADIAL
BEARING
MATCHED ROTOR SET
Roller vanes to reduce friction and

internal leakage and to maintain efficiency.
greater, more consistent volumetric
efficiency.
Wheel mount version available.
More starting torque than competitive
motors in applications where the shaft is
side loaded. (Competitive brands require
more pressure to start the motor.)
A needle-roller mounted coupling shaft
and steel-caged thrust bearing which can
withstand 1000-pound thrust loads.
Side load capacity is 1600 lbs. (727.3 kg)
maximum at center of output shaft.
A unique high-pressure shaft seal that
eliminates the need for case drains, check
valves and extra plumbing.
Greater durability due to superior lubrication and minimum drive spline wear.
Patented 60-40 spline member arrangement transmits more torque with less weight.

4


HY13-1512-004-M1/USA
Torqmotor TF Series features include:
COUPLING SHAFT
HIGH PRESSURE SEAL

NEEDLE THRUST BEARING
HOUSING
DRIVE LINK
12-TOOTH
SPLINES
DIRT & WATER SEAL
NEEDLE RADIAL
BEARING
MATCHED ROTOR SET
Heavy-duty thrust and roller bearings for up to

twice side-load capacity to the previous motor.
Roller vanes to reduce friction and internal
leakage, and to maintain efficiency.
A patented orbiting commutation system for
less wear and longer life.
A patented 60:40 arrangement of internal and
external spline members to transmit more torque
with less weight.
A unique high-pressure shaft seal that eliminates the need for case drains, check valves and
extra plumbing.
A unique manifold designed to improve
operating efficiency.
Up to 1000 lbs. (453.6 kg) end-thrust capacity
in either direction.
A design that is less sensitive to contamination
than competitive motors.
Greater durability because of superior lubrication and minimum drive spline wear.
Superior low speed performance.
greater, more consistent volumetric efficiency.
HIGH PRESSURE SEAL

COUPLING
SHAFT
Torqmotor TG/ TH/TL Series features

include:
NEEDLE THRUST BEARING Roller vanes to reduce friction and internal

HOUSING
DRIVE LINK
14-TOOTH
SPLINES
DIRT & WATER SEAL

NEEDLE RADIAL
BEARING
MATCHED ROTOR SET
leakage and to maintain efficiency.

A patented orbiting commutation system for
less wear and longer life.
A patented 60:40 arrangement of internal and
external spline members to transmit more torque
with less weight.
A unique high-pressure shaft seal that eliminates the need for case drains, check valves and
extra plumbing.
A manifold designed to improve operating
efficiency.
Heavy-duty thrust and roller bearings for up to
twice the side-load capacity to the previous
motor.
Up to 1000 lbs. (453.6 kg) end-thrust capacity
in either direction.
A design that is less sensitive to contamination
than competitive motors.
Greater durability because of superior lubrication and minimum drive spline wear.
greater, more consistent volumetric efficiency.
HY13-1512-004-M1/USA



HY13-1512-004-M1/USA
Introduction
A page with the Torqmotor exploded assembly view is

provided several places in this manual. The component
part names and item numbers assigned on this exploded assembly view correspond with names and item
numbers (in parentheses) used in the disassembly and
assembly procedures set forth in this manual.
Service part list charts are also provided in this manual
with the part names and exploded view item numbers
cross referenced to Parker service part numbers.
Service parts are available through the Original Equipment Manufacturer or Parker approved TC, TB, TE, TJ,
TF, TH and TL Distributors.
As you gain experience in servicing the Torqmotor, you
may find that some information in this manual could be
clearer or more complete. If so, let us know about it. Do
not try to second guess the manual. If you are stuck,
contact us. Servicing the Torqmotor should be a safe
and productive procedure, in order for the unit to deliver
the reliable, long-life operation engineered into it.
This service manual has one purpose: to guide you in

maintaining, troubleshooting, and servicing the TC, TB,
TE, TJ, TF, TH and TL Torqmotor (low-speed, hightorque hydraulic motor).
Material in this manual is organized so you can work on
the Torqmotor and get results without wasting time or
being confused. To get these results, you should read
this entire manual before you begin any work on the
Torqmotor.
This manual also contains troubleshooting information
and checklist. If you must service the Torqmotor, the
checklist will help you to determine where the problem
may be.
The three-column format of the Disassembly and
Inspection, and Assembly sections will make it easier
for you to conduct major work on the Torqmotor.
Column 1 gives a brief key for each procedure. Column
2 explains in detail the procedure you should follow.
Column 3 illustrates this procedure with photographs.
Read all material carefully and pay special attention to
the notes, cautions, and warnings.

HY13-1512-004-M1/USA
Troubleshooting Guide

NOTE: Before troubleshooting any system problem, check service literature published by the equipment and/or
component manufacturers. Follow their instructions, if given, for checking any component other than the
Torqmotor unit.
Preparation
Hydraulic Components
Make your troubleshooting easier by preparing as

follows:
work in a clean, well-lighted place;
have proper tools and materials nearby;
have an adequate supply of clean petroleum-based
solvent.
If you think the problem is caused by a hydraulic

component, start by checking the easy-to-reach items.
Check all hoses and lines for cracks, hardening, or
other signs of wear. Reroute any usable hoses that are
kinked, severely bent, or that rest against hot engine
parts. Look for leaks, especially at couplings and
fittings. Replace any hoses or lines that dont meet
system flow and pressure ratings.
Next, go to the reservoir and filter or filters. Check fluid
level and look for air bubbles. Check the filter(s). A filter
with a maximum 50 micron filtration is recommended for
the TorqmotorTM system.
Visually check other components to see if they are
loosely mounted, show signs of leaks, or other damage
or wear.
Excessive heat in a hydraulic system can create
problems that can easily be overlooked. Every system
has its limitation for the maximum amount of temperature. After the temperature is attained and passed, the
following can occur:
oil seal leaks
loss of efficiency such as speed and torque
pump loss of efficiency
pump failure
hoses become hard and brittle
hose failure
WARNING: SINCE SOLVENTS ARE FLAMMABLE, BE

EXTREMELY CAREFUL WHEN USING ANY SOLVENT, EVEN A SMALL EXPLOSION OR FIRE COULD
CAUSE INJURY OR DEATH.
WARNING: WEAR EYE PROTECTION AND BE SURE
TO COMPLY WITH OSHA AND OTHER MAXIMUM AIR
PRESSURE REQUIREMENTS.
Preliminary Checks
Hydraulic systems are often trouble-free. Hence, the
problem an operator complains of could be cause by
something other than the hydraulic components.
Thus, once you have determined that a problem exists,
start with the easy-to-check items, such as:
parts damaged from impact that were not properly
repaired, or that should have been replaced; and
improper replacement parts used in previous
servicing
mechanical linkage problems such as binding,
broken, or loose parts or slipping belts
A normal temperature range means an efficient hydraulic system. Consult the manuals published by equipment and/or component manufacturers for maximum
allowable temperature and hydraulic tests that may be
necessary to run on the performance of the hydraulic
components. The Torqmotor is not recommended for
hydraulic systems with maximum temperatures above
200F (93.3C).


HY13-1512-004-M1/USA
Troubleshooting Checklist
Trouble
Cause
Remedy
Oil Leakage
1. Hose fittings loose, worn or

damaged.
Check & replace damaged

fittings or O Rings. Torque to
manufacturers specifications.
2.Oil seal rings (4) deteriorated by

excess heat.
Replace oil seal rings by disassembling

Torqmotor unit.
3.Special bolt (1, 1A, 1B or 1C)

loose or its sealing area
deteriorated by corrosion.
(a) Loosen then tighten single bolt to

torque specification.
(b) Replace bolt.
Significant loss of
speed under load
4.Internal shaft seal (16) worn or

damaged.
Replace seal. Disassembly of Torqmotor

unit necessary.
5.Worn coupling shaft (12) and

internal seal (16).
Replace coupling shaft and seal by

disassembling Torqmotor unit.
1. Lack of sufficient oil supply
(a) Check for faulty relief valve and

adjust or replace as required.
(b) Check for and repair worn pump.
(c) Check for and use correct oil for
temperature of operation.
Low mechanical
efficiency or undue
high pressure
required to operate
Torqmotor unit
2.High internal motor leakage
Replace worn rotor set by disassembling

Torqmotor unit.
3.Severely worn or damaged

internal splines.
Replace rotor set, drive link and coupling

shaft by disassembling Torqmotor unit.
4.Excessive heat.
Locate excessive heat source (usually a

restriction) in the system and correct the
condition.
1. Line blockage
Locate blockage source and repair or

replace.
2.Internal interference
Disassemble Torqmotor unit, identify and

remedy cause and repair, replacing parts as
necessary.
3.Lack of pumping pressure
Check for and repair worn pump.
4.Excessive binding or loading in

system external to Torqmotor
unit.
Locate source and eliminate cause.
CAUTION: If the hydraulic system fluid becomes overheated [in excess of 200F (93.3C)], seals in the system
can shrink, harden or crack, thus losing their sealing ability.
9


Tools and Materials Required for Servicing TC,TB, TE, TJ, TF, TG, TH and TL Series
HY13-1512-004-M1/USA
Clean, petroleum-based solvent

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


HY13-1512-004-M1/USA
Technical Information
CONVERSIONS
INCHES
.020
.021
.029
.030
.111
.119
.152
.160
.296
.304
.460
.470
.500
.585
.595
.660
.675
1.058
mm
.51
.53
.74
.76
2.81
3.02
3.86
4.06
7.52
7.72
11.68
11.94
12.70
14.86
15.11
16.76
17.15
26.87
INCHES
1.060
1.295
1.297
1.396
1.398
1.620
1.622
1.983
1.985
2.120
2.122
2.233
2.235
2.483
2.485
2.500
2.88
mm
26.92
32.89
32.94
35.46
35.51
41.15
41.20
50.37
50.42
53.85
53.90
56.72
56.77
63.07
63.12
63.5
73.2
Torque Chart
Part Name
bolt 5/16 24 UNF 2A
bolt 3/8 24 UNF 2A
bolt 5/8 18 UNF 2A
nut 3/4 16 UNF 2B
nut 1-20 UNEF 2B
nut 1-1/8 18 UNEF 2B
Item Number
1, 1A, 1B or 1C
1, 1A, 1B or 1C
12D
12B (TC, TB, TE)
12B (TF, TG, TL)
12B (TG, TH)
Torque
22-26 ft. lbs. (30-35 N m)
45-55 ft. lbs. (60-76 N m)
140-180 ft. lbs. (190-244 N m)
175-255 ft. lbs. (237-305 N m)
300-400 ft. lbs. (407-542 N m)
300-400 ft. lbs. (407-542 N m)
- TC has two steel bushing internal of housing press first steel bushing 1.223 deep
from housing face the second steel bushing press .03 below face
- TL press internal bearing .576 below face.
(Fabricate if considered necessary)

Figure 1 TC, TB & TE
(Fabricate if considered necessary)

Figure 2 TF & TG (see note)
11

HY13-1512-004-M1/USA
Disassembly and Inspection

Preparation Before Disassembly

Before you disassemble the Torqmotor unit or any of its components read this entire manual. It provides
important information on parts and procedures you will need to know to service the Torqmotor.
Determine whether the Torqmotor you are about to disassemble is the Small Frame Series TC, TB, TE or TJ or
the Large Frame Series TF, TG, TL or TH so you can follow those procedures that pertain to that Series
Torqmotor. The first two letters of the spec number on the Torqmotor identification tag is the Series designation. Also determine the type of end construction from the alternate views shown on the exploded view.
The Small Frame Series TC, TB & TE Torqmotors will have a 3.66 inch (92.9 mm) main body outside diameter
and five or six 5/16-24 UNF 2A cover bolts. The Medium Frame Series TJ Torqmotors will have a 3.66 inch (92.9
mm) main body outside diameter and six 5/16-24 UNF 2A cover bolts. The Large Frame Series TF, TG, TL & TH
Torqmotors will have a 5 inch (127.9 mm) main body outside diameter and seven 3/8 24 UNF 2A cover bolts.
Refer to Tools and Materials Required for Services section for tools and other items required to service the
Torqmotor and have them available.
Thoroughly clean off all outside dirt, especially from around fittings and hose connections, before disconnecting
and removing the Torqmotor. Remove rust or corrosion from coupling shaft.
Remove coupling shaft connections and hose fittings and immediately plug port holes and fluid lines.
Remove the Torqmotor from system, drain it of fluid and take it to a clean work surface.
Clean and dry the Torqmotor before you start to disassemble the unit.
As you disassemble the Torqmotor clean all parts, except seals, in clean petroleum-based solvent, and blow
them dry.
WARNING: petroleum-base solvents are flammable. Be extremely careful when using any solvent. Even a small
explosion or fire could cause injury or death.
WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR
PRESSURE REQUIREMENTS.
CAUTION: Never steam or high pressure wash hydraulic components. Do not force or abuse closely fitted parts.
Keep parts separate to avoid nicks and burrs.
Discard all seals and seal rings as they are removed from the Torqmotor. Replace all seals, seal rings and any
damaged or worn parts with genuine Parker or OEM approved service parts.
28


HY13-1512-004-M1/USA
Reference Exploded Assembly View

Place
Torqmotor
in a vise
WARNING
1. Place the Torqmotor in a soft jawed vice,

with coupling shaft (12) pointed down and the
vise jaws clamping firmly on the sides of the
housing (18) mounting flange or port bosses.
Remove manifold port O-Rings (18A) if
applicable.
WARNING: IF THE TORQMOTOR IS NOT
FIRMLY HELD IN THE VISE, IT COULD BE
DISLODGED DURING THE SERVICE
PROCEDURES, CAUSING INJURY.
Scribe alignment 2. Scribe an alignment mark down and across

mark & loose
the Torqmotor components from end cover
valve plugs
(2) to housing (18) to facilitate reassembly
orientation where required. Loosen two shuttle
or relief valve plugs (21) for disassembly later
if included in end cover. 3/16 or 3/8 inch Allen
wrench or 1 inch hex socket required. SEE
FIGURES 3 & 4.
Figure 3
Figure 4
Figure 5
Remove special
bolts &
inspect bolts
3. Remove the five, six, or seven special ring

head bolts (1, 1A, 1B, or 1C) using an
appropriate 1/2 or 9/16 inch size socket. SEE
FIGURE 5. Inspect bolts for damaged
threads, or sealing rings, under the bolt head.
Replace damaged bolts. SEE FIGURE 6.
Figure 6
29

HY13-1512-004-M1/USA

Remove end
cover &
inspect bolts
NOTE

4. Remove end cover assembly (2) and seal

ring (4). Discard seal ring. SEE FIGURE 7.
NOTE: Refer to the appropriate alternate

cover construction on the exploded view
to determine the end cover construction
being serviced.
Figure 7
Remove plugs
and valves
5. If the end cover (2) is equipped with shuttle

valve or relief valve (24) components,
remove the two previously loosened plugs
(21) and o-rings (22). SEE FIGURE 8.
CAUTION
CAUTION: Be ready to catch the shuttle

valve or relief valve components that will
fall out of the end cover valve cavity when
the plugs are removed.
NOTE
NOTE: O-ring (22) is not included in seal

kits but serviced separately if required.
NOTE
NOTE: The insert and if included the

orifice plug in the end cover (2) must not
be removed as they are serviced as an
integral part of the end cover.
Wash & inspect

end cover
Figure 8
6. Thoroughly wash end cover (2) in proper

solvent and blow dry. Be sure the end cover
valve apertures, including the internal orifice
plug, are free of contamination. Inspect end
cover for cracks and the bolt head recesses
for good bolt head sealing surfaces. Replace
end cover as necessary. SEE FIGURE 9.
Figure 9
NOTE
Remove &
inspect
commutator
ring
NOTE: A polished pattern (not scratches)

on the cover from rotation of the commutator (5) is normal. Discoloration would
indicate excess fluid temperature, thermal
shock, or excess speed and require
system investigation for cause and close
inspection of end cover, commutator,
manifold, and rotor set.
7. Remove commutator ring (6). SEE FIGURE 10.
Inspect commutator ring for cracks, or burrs.
Figure 10
30


HY13-1512-004-M1/USA

Remove &
inspect
commutator
8. Remove commutator (5) and seal ring (3)

Remove seal ring from commutator, using an
air hose to blow air into ring groove until seal
ring is lifted out and discard seal ring. Inspect
commutator for cracks or burrs, wear, scoring,
spalling or brinelling. If any of these conditions
exist, replace commutator and commutator
ring as a matched set. SEE FIGURE 11 & 12.
Remove
manifold
9. Remove manifold (7) and inspect for cracks

surface scoring, brinelling or spalling. Replace
manifold if any of these conditions exist. SEE
FIGURE 13. A polished pattern on the ground
surface from commutator or rotor rotation is
normal. Remove and discard the seal rings (4)
that are on both sides of the manifold.
NOTE
Remove &
inspect
rotor set &
wearplate
NOTE
Figure 11
NOTE:The manifold is constructed of plates

bonded together to form an integral component not subject to further disassembly for
service. Compare configuration of both sides
of the manifold to ensure that same surface is
reassembled against the rotor set.
10. Remove rotor set (8) and wearplate (9),
together to retain the rotor set in its assembled
form, maintaining the same rotor vane (8C) to
stator (8B) contact surfaces. SEE FIGURE 14.
The drive link (10) may come away from the
coupling shaft (12) with the rotor set, and
wearplate. You may have to shift the rotor set
on the wearplate to work the drive link out of
the rotor (8A) and wearplate. SEE FIGURE 15.
Inspect the rotor set in its assembled form for
nicks, scoring, or spalling on any surface and
for broken or worn splines. If the rotor set
component requires replacement, the complete
rotor set must be replaced as it is a matched
set. Inspect the wearplate for cracks, brinelling,
or scoring. Discard seal ring (4) that is between
the rotor set and wearplate.
NOTE: The rotor set (8) components may
become disassembled during service
procedures. Marking the surface of the rotor
and stator that is facing UP, with etching ink
or grease pencil before removal from
Torqmotor will ensure correct reassembly
of rotor into stator and rotor set into
Torqmotor. Marking all rotor components
and mating spline components for exact
repositioning at assembly will ensure
maximum wear life and performance of
rotor set and Torqmotor.
31
Figure 12
Figure 13
Figure 14
HY13-1512-004-M1/USA

NOTE
NOTE: Series TG or TH may have a rotor set

with two stator halves (8B & 8D) with a seal
ring (4) between them and two sets of seven
vanes (8C & 8E). Discard seal ring only if
stator halves become disassembled during
the service procedures.
NOTE
NOTE: A polished pattern on the wear

plate from rotor rotation is normal.
Check rotor,
vance clearance
Figure 15
11. Place rotor set (8) and wear plate (9) on a flat
surface and center rotor (8A) in stator (8B)
such that two rotor lobes (180 degrees apart)
and a roller vane (8C) centerline are on the
same stator centerline. Check the rotor lobe
to roller vane clearance with a feeler gage at
this common centerline. If there is more than
.005 inches (0.13 mm) of clearance, replace
rotor set. SEE FIGURE 16.
Figure 16
NOTE
Remove &
inspect
drive link
Remove thrust
bearing
NOTE: If rotor set (8) has two stator halves

(8B & 8D) and two sets of seven vanes (8C
& 8E) as shown in the alternate construction TG rotor set assembly view, check the
rotor lobe to roller vane clearance at both
ends of rotor.
12. Remove drive link (10) from coupling shaft

(12) if it was not removed with rotor set and
wear plate. Inspect drive link for cracks and
worn or damaged splines. No perceptible lash
(play) should be noted between mating spline
parts. SEE FIGURE 17. Remove and discard
seal ring (4) from housing (18).
Figure 17
13. Remove thrust bearing (11) from top of

coupling shaft (12) if Torqmotor is a Series
TF, TG, TH or TL. Inspect for wear, brinelling,
corrosion and a full complement of retained
rollers. SEE FIGURE 18.
Figure 18
32


HY13-1512-004-M1/USA

Check coupling
shaft for rust
or corrosion
14. Check exposed portion of coupling shaft (12)

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

the output end of shaft. SEE FIGURE 20.
Inspect coupling shaft bearing and seal
surfaces for spalling, nicks, grooves, severe
wear or corrosion and discoloration. Inspect
for damaged or worn internal and external
splines or keyway. SEE FIGURE 21. Replace
coupling shaft if any of these conditions
exist.
NOTE
NOTE: Minor shaft wear in seal area is

permissible. If wear exceeds .020 inches
(0.51 mm) diametrically, replace coupling
shaft.
NOTE
NOTE: A slight polish is permissible in

the shaft bearing areas. Anything more
would require coupling shaft replacement.
Remove seal
ring from
housing
16. Remove and discard seal ring (4) from

housing (18).
Remove &
inspect thrust
washer &
thrust bearing
17. Remove thrust bearing (15) and thrust washer

(14) if the unit is a Series TC, TB or TE.
Inspect for wear, brinelling, corrosion and a full
complement of retained rollers. SEE FIGURE
22. Note: The TL motor has only one thrust
bearing and washer.
Figure 20
Figure 21
NOTE
NOTE: Large Frame Series TF, TG & TJ
Torqmotors have a thrust bearing (15)
sandwiched between two thrust washers
(14) that cannot be removed from housing
(18) unless bearing (13) is removed for
replacement.
33
Figure 22
HY13-1512-004-M1/USA

Remove seal
& washer or
washers

18. Remove seal (16) and back up ring (17) from

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

& Small Frame Torqmotors did not
include backup washer (25), but must
include backup washer (25) when reassembled for service.
Figure 24
Remove seal
19. Remove housing (18) from vise, invert it and

remove and discard seal (20). A blind hole
bearing or seal puller is required.
SEE FIGURE 25.
Figure 25
Inspect
housing
assembly
20. Inspect housing (18) assembly for cracks,

the machined surfaces for nicks, burrs,
brinelling or corrosion. Remove burrs that can
be removed without changing dimensional
characteristics. Inspect tapped holes for
thread damage. SEE FIGURE 26. If the
housing is defective in these areas, discard
the housing assembly.
Figure 26
34


HY13-1512-004-M1/USA

Inspect housing
bearing/bushing
NOTE
21. If the housing (18) assembly has passed

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

bushing (13) in relation to the housing
wear plate surface and the depth or
location of bearing/bushing (19) in relation to the beginning of bearing/bushing
counter bore should be measured and
noted before removing the bearings/
bushings. This will facilitate the correct
reassembly of new bearings/bushings.
SEE FIGURE 29.
Figure 27
Figure 28
Figure 29
Remove
bearings
or bushings
& thrust
washers
22. If the bearings, bushing or thrust washers

must be replaced use a suitable size bearing
puller to remove bearing/bushings (19) and
(13) from housing (18) without damaging the
housing. Remove thrust washers (14) and
thrust bearing (15) if they were previously
retained in the housing by bearing (13). SEE
FIGURES 30 & 31.
Figure 30
THE DISASSEMBLY OF TORQMOTOR IS COMPLETED.

35
Figure 31
HY13-1512-004-M1/USA
Torqmotor Assembly

Replace all seals and seal rings with new ones each time you reassemble the Torqmotor unit. Lubricate all
seals and seal rings with SAE 10W40 oil or clean grease before assembly.
NOTE: Individual seals and seal rings as well as a complete seal kit are available. SEE FIGURE 32. The
parts should be available through most OEM parts distributors or Parker approved Torqmotor distributors. (Contact your local dealer for availability).
NOTE: Unless otherwise indicated, do not oil or grease parts before assembly.
Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove
any paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear plate and
housing and from port and sealing areas.
WARNING
WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN

USING ANY SOLVENT. EVEN A SMALL
EXPLOSION OR FIRE COULD CAUSE
INJURY OR DEATH.
WARNING
WARNING: WEAR EYE PROTECTION AND

BE SURE TO COMPLY WITH OSHA OR
OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.
Press in outer
bearing/bushing
1. If the housing (18) bearing components were

removed for replacement, thoroughly coat and
pack a new outer bearing/bushing (19) with
clean corrosion resistant grease recommended
in the material section. Press the new bearing/
bushing into the counterbore at the mounting
flange end of the housing, using the appropriate sized bearing mandrel such as described in
figure 1 or figure 2 which will control the
bearing/ bushing depth.
Small Frame Series TB and TE Torqmotor
housings require the use of bearing mandrel
shown in figure 1 to press bearing/ bushing
(19) into the housing to a required depth of
.151/.161 inches (3.84/4.09 mm) from the end
of the bearing counterbore. SEE FIGURE 33.
(TC reference page 10).
Figure 32, TF, TG seal kit
Figure 33
Large Frame Series TF, TG & TJ Torqmotor

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

HY13-1512-004-M1/USA
Torqmotor Assembly
NOTE
NOTE: Bearing mandrel must be pressed

against the lettered end of bearing shell.
Take care that the housing bore is square
with the press base and the bearing/
bushing is not cocked when pressing a
bearing/bushing into the housing.
CAUTION
CAUTION: If the bearing mandrel specified

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

(13) and (19) have a press fit into the
housing they must be discarded when
removed. They must not be reused.
Figure 36
Press in inner
bearing/bushing
2. The Small Frame Series TB and TE

Torqmotor inner housing bearing/bushing (13)
can now be pressed into its counterbore in
housing (18) flush to .03 inch (.76 mm) below
the housing wear plate contact face. Use the
opposite end of the bearing mandrel that was
used to press in the outer bearing/bushing (19).
Reference figure 1, Tools and Materials
Required for Servicing section. SEE FIGURE
36.
The Large Frame Series TF, TG & TJ
Torqmotor housing (18) requires that you
assemble a new backup washer (25) &
backup ring (17), new seal (16), with the lip
facing to the inside of Torqmotor (see figure
69A), new thrust washer (14), new thrust
bearing (15) and a new second thrust washer
(14) in that order before pressing in the inner
housing bearing (13). SEE FIGURE 37 & 38.
When these components are in place, press
new bearing (13) into the housing (18) to a
depth of .105/.125 inches (2.67/3.18), .03
inches max for TJ (.76) below the housing
wear plate contact face. Use the opposite
end of the bearing mandrel used to press in
outer bearing (19). Reference figure 2, in the
Tools and Materials Required for Servicing
section. SEE FIGURE 39.
37
Figure 37
Figure 38
HY13-1512-004-M1/USA
Torqmotor Assembly
Press in dirt &
water seal

3. Press a new dirt and water seal (20) into the

housing (18) outer bearing counterbore.
Figure 39
The Small Frame Series TC, TB and TE

Torqmotor dirt and water seal (20) must be
pressed in until its flange is flush against the
housing. SEE FIGURE 40.
Figure 40
The Large Frame Series TF, TG, TJ & TH

Torqmotor dirt and water seal (20) must be
pressed in with the lip facing out and until the
seal is flush to .020 inches (.51 mm) below
the end of housing. SEE FIGURE 41.
Figure 41
Place housing
assembly
into vice
4. Place housing (18) assembly into a soft

jawed vise with the coupling shaft bore down,
clamping against the mounting flange. SEE
FIGURE 42.
Figure 42
38


HY13-1512-004-M1/USA
Torqmotor Assembly
Assemble backup 5. On Small Frame, Series TC, TB & TE

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

& TG Torqmotors that do not have
backup washer (25) when disassembled
must be assembled with a new backup
ring (17), new backup washer (25), and
new seal (16).
Figure 43
Figure 44
Assemble thrust 6. Assemble thrust washer (14) then thrust

bearing (15) that was removed from the Series
washer & bearing
TB or TE Torqmotor. SEE FIGURE 45.
NOTE
Apply masking
tape to shaft
NOTE: Small Frame Series TC, TB and TE

Torqmotors require one thrust washer
(14) with thrust bearing (15). The coupling
shaft will be seated directly against the
thrust bearing.
Figure 45
7. Apply masking tape around splines or

keyway on shaft (12) to prevent damage to
seal. SEE FIGURE 46.
Figure 46
39

HY13-1512-004-M1/USA
Torqmotor Assembly

Install
coupling
shaft
8. Be sure that a generous amount of clean

corrosion resistant grease has been applied to
the lower (outer) housing bearing/bushing (19).
Install the coupling shaft (12) into housing (18),
seating it against the thrust bearing (15) in TC,
TB and TE Series housings and against the
second thrust washer (14) in TF and TG Series
housings. SEE FIGURE 47.
CAUTION
CAUTION: The outer bearing (19) is not

lubricated by the systems hydraulic fluid.
Be sure it is thoroughly packed with the
recommended grease, Parker Gear grease
specification #045236, E/M Lubricant
#K-70M.
NOTE
NOTE: Mobil Mobilith SHC 460

NOTE: A 102 Tube (P/N 406010) is included
in each seal kit.
NOTE
NOTE: The coupling shaft (12) will be flush

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

coupling shaft (12) only if you are servicing an
TF, TG, TH or TL Series Torqmotor.
SEE FIGURE 49.
Insert seal
ring
10. Apply a small amount of clean grease to a

new seal ring (4) and insert it into the housing
(18) seal ring groove. SEE FIGURE 50.
NOTE
NOTE: One or two alignment studs

screwed finger tight into housing (18) bolt
holes, approximately 180 degrees apart,
will facilitate the assembly and alignment
of components as required in the following procedures. The studs can be made by
cutting off the heads of either
3/8-24 UNF 2A or 5/16-24 UNF 2A bolts as
required that are over .5 inch (12.7 mm)
longer than the bolts (1, 1A, 1B, or 1C)
used in the Torqmotor.
40
Figure 47
Figure 48
Figure 49
Figure 50

HY13-1512-004-M1/USA
Torqmotor Assembly
Install
drive link
NOTE
11. Install drive link (10) the long splined end

down into the coupling shaft (12) and engage
the drive link splines into mesh with the
coupling shaft splines. SEE FIGURE 51.
NOTE: Use any alignment marks put on
the coupling shaft and drive link before
disassembly to assemble the drive link
splines in their original position in the
mating coupling shaft splines.
Figure 51
Assemble
wear plate
12. Assemble wear plate (9) over the drive link

(10) and alignment studs onto the housing
(18). SEE FIGURE 52.
Assemble
seal ring
13. Apply a small amount of clean grease to a

new seal ring (4) and assemble it into the
seal ring groove on the wear plate side of the
rotor set stator (8B). SEE FIGURE 53.
Install the
assembled
rotor set
14. Install the assembled rotor set (8) onto wear

plate (9) with rotor (8A) counterbore and seal
ring side down and the splines into mesh with
the drive link splines. SEE FIGURE 54.
NOTE
NOTE: It may be necessary to turn one

alignment stud out of the housing (18)
temporarily to assemble rotor set (8) or
manifold (7) over the drive link.
NOTE
NOTE: If necessary, go to the appropriate,

Rotor Set Component Assembly
Procedure.
NOTE
NOTE: The rotor set rotor counterbore side

must be down against wear plate for drive
link clearance and to maintain the original
rotor-drive link spline contact. A rotor set
without a counterbore and that was not
etched before disassembly can be reinstalled using the drive link spline pattern
on the rotor splines if apparent, to determine which side was down. The rotor set
seal ring groove faces toward the wear
plate (9).
41
Figure 52
Figure 53
Figure 54
HY13-1512-004-M1/USA
Torqmotor Assembly
Assemble
seal ring
in manifold
NOTE
Assemble
manifold

15. Apply clean grease to a new seal ring (4) and

assemble it in the seal ring groove in the
rotor set contact side of manifold (7). SEE
FIGURE 55.
NOTE: The manifold (7) is made up of
several plates bonded together permanently to form an integral component. The
manifold surface that must contact the
rotor set has its series of irregular shaped
cavities on the largest circumference or
circle around the inside diameter. The
polished impression left on the manifold
by the rotor set is another indication of
which surface must contact the rotor set.
Figure 55
16. Assemble the manifold (7) over the alignment

studs and drive link (10) and onto the rotor
set. Be sure the correct manifold surface is
against the rotor set. SEE FIGURE 56.
Figure 56
Insert a seal
in manifold
17. Apply grease to a new seal ring (4) and

insert it in the seal ring groove exposed on
the manifold. SEE FIGURE 57.
Figure 57
Assemble
commutator ring
18. Assemble the commutator ring (6) over

alignment studs onto the manifold. SEE
FIGURE 58.
Figure 58
42


HY13-1512-004-M1/USA
Torqmotor Assembly
Assemble
seal &
commutator
19. Assemble a new seal ring (3) flat side up,

into commutator (5) and assemble commutator over the end of drive link (10) onto
manifold (7) with seal ring side up. SEE
FIGURE 59, 60.
Figure 59
Figure 60
Assemble shuttle 20. If shuttle valve components items #21, #22,

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

#24 were removed from the end cover (2)
assemble a new o-ring (22) on the two plugs
(21). Assemble a two piece relief valve (24) in
each of the plugs, with the large end of the
conical spring into the plug first and the small
nut of the other valve piece in the small end
of the conical spring. Turn each of the plug
and relief valve assemblies into the end
cover loosely to be torqued later. 3/8 inch
Allen or 1 inch Hex socket required. SEE
FIGURE 62.
43
Figure 62
HY13-1512-004-M1/USA
Torqmotor Assembly
Assemble seal
ring &
end cover

22. Assemble a new seal ring (4) into end cover

(2) and assemble end cover over the alignment studs and onto the commutator set.
SEE FIGURE 63, 64. If the end cover has
only 5 bolt holes be sure the cover holes are
aligned with the 5 threaded holes in housing
(18). The correct 5 bolt end cover bolt hole
relationship to housing port bosses is shown
in FIGURE 65.
Figure 63
NOTE
NOTE: If the end cover has a valve (24) or

has five bolt holes, use the line you
previously scribed on the cover to radially
align the end cover into its original
position.
Figure 64
Figure 65
Assemble
cover bolts
23. Assemble the 5, 6 or 7 special bolts (1, 1A,

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

HY13-1512-004-M1/USA
Torqmotor Assembly
NOTE
NOTE: The special bolts required for use

with the relief or shuttle valve (24) end
cover assembly (2) are longer than the
bolts required with standard and cover
assembly. Refer to the individual service
parts lists or parts list charts for correct
service part number if replacement is
required.
Figure 67
Figure 68
Torque the
valve plugs
24. Torque the two shuttle valve plug assemblies

(21) in end cover assembly to 9-12 ft. lbs.
(12-16 N m) if cover is so equipped. SEE
FIGURE 69.
Torque the two relief valve plug assemblies
(21) in end cover assembly to 45-55 ft. lbs.
(61-75 N m) if cover is so equipped.
Figure 69
Thrust
Washers
Thrust
Washers
Housing
Housing
Backup
Washer
Backup Washer
Seal
Seal
Backup
Ring
Thrust
Bearing
Not To Scale
Shaft
Figure 69A
Not To Scale
Large Frame
Backup
Ring
Thrust
Bearing
Figure 69B
Shaft
Small Frame
THE ASSEMBLY OF THE TORQMOTOR IS NOW COMPLETE EXCEPT FOR WOODRUFF KEY (12A), NUT
(12B), WASHER (12C), BOLT (12D), LOCKWASHER (12E), RETAINER RING (12F) or PORT O-RINGS (18A) AT
INSTALLATION IF APPLICABLE. PROCEED TO FINAL CHECKS SECTION.
45

HY13-1512-004-M1/USA

One Piece Stator Construction

A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembled
by the following procedures.
Assemble stator
1. Place stator (8B) onto wear plate (9) with seal

ring (4) side down, after following Torqmotor
assembly procedures 1 through 13. Be sure
the seal ring is in place. SEE FIGURE 70.
Insert
two bolts
2. If assembly alignment studs are not being

utilized, align stator bolt holes with wear plate
and housing bolt holes and turn two bolts (1)
finger tight into bolt holes approximately 180
degrees apart to retain stator and wear plate
stationary.
Assemble rotor
NOTE
Assemble vanes
CAUTION
Figure 70
3. Assemble the rotor (8A), counterbore down if

applicable, into stator (8B), and onto wear
plate (9) with rotor splines into mesh with
drive link (10) splines. SEE FIGURE 71.
NOTE: If the manifold side of the rotor was
etched during Torqmotor disassembly,
this side should be up. If the rotor is not
etched and does not have a counterbore,
use the drive link spline contact pattern
apparent on the rotor splines to determine
the rotor side that must be against the
wear plate.
Figure 71
4. Assemble six vanes (8C), or as many vanes

that will readily assemble into the stator vane
pockets. SEE FIGURE 72.
CAUTION: Excessive force used to push the
rotor vanes into place could shear off the
coating applied to the stator vane pockets.
Assemble full
complement
of vanes
5. Grasp the output end of coupling shaft (12)

with locking pliers or other appropriate
turning device and rotate coupling shaft, drive
link and rotor to seat the rotor and the
assembled vanes (8C) into stator (8B),
creating the necessary clearance to assemble the seventh or full complement of
seven vanes. Assemble the seven vanes
using minimum force. SEE FIGURE 73.
Remove two
assembled bolts
6. Remove the two assembled bolts (1) if used

to retain stator and wear plate.
Go to Torqmotor assembly procedure #15,
to continue Torqmotor assembly.
46
Figure 72
Figure 73

HY13-1512-004-M1/USA
Two Piece Stator Construction

A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be
assembled by the following procedures.
Assemble
stator halves
1. Place stator half (8B) onto wear plate (9) with

seal ring (4) side down, after following
Torqmotor assembly procedures 1 through 13.
Be sure the seal ring is in place.
Insert two
alignment
studs
2. Align stator bolt holes with wear plate and

housing bolts and turn two alignment studs finger
tight into bolt holes approximately 180 degrees
apart to retain stator half and wear plate stationary.
Assemble rotor
3. Assemble rotor (8A), counterbore down if applicable, into stator half (8B), and onto wear plate
(9) with rotor splines into mesh with drive link (10)
splines.
NOTE
Assemble vanes
CAUTION
NOTE: Use any marking you applied to rotor

set components to reassemble the components in their original relationship to ensure
ultimate wear life and performance.
4. Assemble six vanes (8C), or as many vanes that

will readily assemble into the stator vane pockets.
CAUTION: Excessive force used to push the
rotor vanes into place could shear off the
coating applied to the stator vane pockets.
Assemble full
complement
of vanes
5. Grasp the output end of coupling shaft (12) with

locking pliers or other appropriate turning device
and rotate coupling shaft, drive link and rotor to
seat the rotor and the assembled vanes (8C) into
stator half (8B), creating the necessary clearance
to assemble the seventh or full complement of
seven vanes. Assemble the seven vanes using
minimum force.
Assemble seal
ring in stator
half
6. Place second stator half (8D) on a flat surface

with seal ring groove up. Apply a small amount of
grease to a new seal ring (4) and assemble it into
stator half ring groove.
47

HY13-1512-004-M1/USA

Assemble second
stator half
CAUTION

7. Assemble the second stator half (8D) over the

two alignment studs and rotor (8A) with seal ring
side down onto the first stator half (8B) aligning
any timing marks applied for this purpose.
CAUTION: If the stator half (8B) is a different

height (thickness) than stator half (8D) the
stator vanes (8C) or (8E) of the same length
(height) as the stator half must be reassembled in their respective stator half for the
rotor set to function properly.
Assemble vanes
8. Assemble six vanes (8E), or as many vanes that

will readily assemble into the stator vane pockets.
Assemble full
complement
of vanes
9. Grasp the output end of coupling shaft (12) with

locking pliers or other appropriate turning device
and rotate coupling shaft, drive link and rotor to
seat the rotor and the assembled vanes (8E) into
stator (8D), creating the necessary clearance to
assemble the seventh or full complement of
seven vanes. Assemble the seven vanes using
minimum force.
Go to Torqmotor assembly procedure #15, to
continue Torqmotor assembly.
48


HY13-1512-004-M1/USA
Final Checks
Final Checks
Pressurize the Torqmotor with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for
external leaks.
Check Torqmotor for rotation. Torque required to rotate coupling shaft should not be more than
50 ft. lbs. (68 N m)
On TB, TE & TJ Series Torqmotors, pressure port with A cast under it on housing (18) is for clockwise
coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with B cast under
it is for counter clockwise coupling shaft rotation.
On TF, TG, & TH Series Torqmotors, pressure port with B cast under it on housing (18) is for clockwise
coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with A case under
it is for counter clockwise coupling shaft rotation.
Use test stand if available, to check operation of the Torqmotor.
Hydraulic Fluid
Keep the hydraulic system filled with one of the following:
10W40 SE or SF manufacturers suggested oil.
Hydraulic fluid as recommended by equipment manufacturer, but the viscosity should not drop below 50 SSU or
contain less than .125% zinc anti-wear additives.
CAUTION: Do not mix oil types. Any mixture, or an unapproved oil, could deteriorate the seals. Maintain
the proper fluid level in the reservoir. When changing fluid, completely drain old oil from the system. It
is suggested also that you flush the system with clean oil.
Filtration
Recommended filtration 20-50 micron.
Oil Temperature
Maximum operating temperature 200F (93.3 C).
49

HY13-1512-004-M1/USA
Tips

Tips for Maintaining the Torqmotor Hydraulic System
Adjust fluid level in reservoir as necessary.
Encourage all operators to report any malfunction or accident that may have damaged the hydraulic system
or component.
Do not attempt to weld any broken Torqmotor component. Replace the component with original equipment
only.
Do not cold straighten, hot straighten, or bend any Torqmotor part.
Prevent dirt or other foreign matter from entering the hydraulic system. Clean the area around and the filler caps
before checking oil level.
Investigate and correct any external leak in the hydraulic system, no matter how minor the leak.
Comply with manufacturers specifications for cleaning or replacing the filter.

CAUTION: Do not weld, braze, solder or any way alter any Torqmotor component.
CAUTION: Maximum operating pressure must not exceed recommended Torqmotor pressure capacity.
CAUTION: Always carefully inspect any system component that may have been struck or damaged
during operation or in an accident. Replace any component that is damaged or that is questionable.
CAUTION: Do not force any coupling onto the Torqmotor coupling shaft as this could damage the unit
internally.
Parker extends close technical cooperation and assistance. If problems occur which you cannot solve, please
contact your local Parker approved Distributor or Parker Technical Support. Our phone number and fax number
and address are on the back cover of this manual.
50


HY13-1512-004-M1/USA
Notes
51

HY13-1512-004-M1/USA
Notes

52


HY13-1512-004-M1/USA
Notes
53

HY13-1512-004-M1/USA
Notes

54


HY13-1512-004-M1/USA
Offer of Sale
The items described in this document and other documents or descriptions provided by Parker Hannifin Corporation, its subsidiaries and its authorized
distributors are hereby offered for sale at prices to be established by Parker Hannifin Corporation, its subsidiaries and its authorized distributors. This
offer and its acceptance by any customer ("Buyer") shall be governed by all of the following Terms and Conditions. Buyers order for any such items,
when communicated to Parker Hannifin Corporation, its subsidiary or an authorized distributor ("Seller") verbally or in writing, shall constitute acceptance
of this offer.
right to alter, discard or otherwise dispose of any special tooling or other
property in its sole discretion at any time.
8. Buyers Property: Any designs, tools, patterns, materials, drawings,
confidential information or equipment furnished by Buyer or any other
items which become Buyers property, may be considered obsolete and
may be destroyed by Seller after two (2) consecutive years have elapsed
without Buyer placing an order for the items which are manufactured using
such property, Seller shall not be responsible for any loss or damage to
such property while it is in Sellers possession or control.
9. Taxes: Unless otherwise indicated on the face hereof, all prices and
charges are exclusive of excise, sales, use, property, occupational or like
taxes which may be imposed by any taxing authority upon the manufacture, sale or delivery of the items sold hereunder. If any such taxes must
be paid by Seller or if Seller is liable for the collection of such tax, the amount
thereof shall be in addition to the amounts for the items sold. Buyer agrees
to pay all such taxes or to reimburse Seller therefore upon receipt of its
invoice. If Buyer claims exemption from any sales, use or other tax imposed
by any taxing authority, Buyer shall save Seller harmless from and against
any such tax, together with any interest or penalties thereon which may
be assessed if the items are held to be taxable.
10. Indemnity For Infringement of Intellectual Property Rights: Seller
shall have no liability for infringement of any patents, trademarks,
copyrights, trade dress, trade secrets or similar rights except as provided
in this Part 10. Seller will defend and indemnify Buyer against allegations
of infringement of U.S. Patents, U.S. Trademarks, copyrights, trade dress
and trade secrets (hereinafter Intellectual Property Rights). Seller will
defend at its expense and will pay the cost of any settlement or damages
awarded in an action brought against Buyer based on an allegation that
an item sold pursuant to this contract infringes the Intellectual Property
Rights of a third party. Sellers obligation to defend and indemnify Buyer
is contingent on Buyer notifying Seller within ten (10) days after Buyer
becomes aware of such allegations of infringement, and Seller having sole
control over the defense of any allegations or actions including all
negotiations for settlement or compromise. If an item sold hereunder is
subject to a claim that it infringes the Intellectual Property Rights of a third
party, Seller may, at its sole expense and option, procure for Buyer the
right to continue using said item, replace or modify said item so as to make
it noninfringing, or offer to accept return of said item and return the
purchase price less a reasonable allowance for depreciation. Notwithstanding the foregoing, Seller shall have no liability for claims of infringement based on information provided by Buyer, or directed to items
delivered hereunder for which the designs are specified in whole or part
by Buyer, or infringements resulting from the modification, combination or
use in a system of any item sold hereunder. The foregoing provisions of
this Part 10 shall constitute Sellers sole and exclusive liability and Buyers
sole and exclusive remedy for infringement of Intellectual Property Rights.
If a claim is based on information provided by Buyer or if the design for
an item delivered hereunder is specified in whole or in part by Buyer, Buyer
shall defend and indemnify Seller for all costs, expenses or judgments
resulting from any claim that such item infringes any patent, trademark,
copyright, trade dress, trade secret or any similar right.
11. Force Majeure: Seller does not assume the risk of and shall not be
liable for delay or failure to perform any of Sellers obligations by reason
of circumstances beyond the reasonable control of Seller (hereinafter
Events of Force Majeure). Events of Force Majeure shall include without
limitation, accidents, acts of God, strikes or labor disputes, acts, laws, rules
or regulations of any government or government agency, fires, floods,
delays or failures in delivery of carriers or suppliers, shortages of materials
and any other cause beyond Sellers control.
12. Entire Agreement/Governing Law: The terms and conditions set
forth herein, together with any amendments, modifications and any
different terms or conditions expressly accepted by Seller in writing, shall
constitute the entire Agreement concerning the items sold, and there are
no oral or other representations or agreements which pertain thereto. This
Agreement shall be governed in all respects by the law of the State of Ohio.
No actions arising out of the sale of the items sold hereunder or this
Agreement may be brought by either party more than two (2) years after
the cause of action accrues.
9/91-P
1. Terms and Conditions of Sale: All descriptions, quotations, proposals,

offers, acknowledgments, acceptances and sales of Sellers products are
subject to and shall be governed exclusively by the terms and conditions
stated herein. Buyers acceptance of any offer to sell is limited to these
terms and conditions. Any terms or conditions in addition to, or inconsistent with those stated herein, proposed by Buyer in any acceptance of
an offer by Seller, are hereby objected to. No such additional, different
or inconsistent terms and conditions shall become part of the contract
between Buyer and Seller unless expressly accepted in writing by Seller.
Sellers acceptance of any offer to purchase by Buyer is expressly
conditional upon Buyers assent to all the terms and conditions stated
herein, including any terms in addition to, or inconsistent with those
contained in Buyers offer, Acceptance of Sellers products shall in all
events constitute such assent.
2. Payment: Payment shall be made by Buyer net 30 days from the date
of delivery of the items purchased hereunder. Amounts not timely paid
shall bear interest at the maximum rate permitted by law for each month
or portion thereof that the Buyer is late in making payment. Any claims
by Buyer for omissions or shortages in a shipment shall be waived unless
Seller receives notice thereof within 30 days after Buyers receipt of the
shipment.
3. Delivery: Unless otherwise provided on the face hereof, delivery shall
be made F.O.B. Sellers plant. Regardless of the method of delivery,
however, risk of loss shall pass to Buyer upon Sellers delivery to a carrier.
Any delivery dates shown are approximate only and Seller shall have no
liability for any delays in delivery.
4. Warranty: Seller warrants that the items sold hereunder shall be free
from defects in material or workmanship for a period of 18 months from
date of shipment from Parker Hannifin Corporation. THIS WARRANTY
COMPRISES THE SOLE AND ENTIRE WARRANTY PERTAINING TO
ITEMS PROVIDED HEREUNDER. SELLER MAKES NO OTHER WARRANTY, GUARANTEE, OR REPRESENTATION OF ANY KIND WHATSOEVER. ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED
TO, MERCHANTABILITY AND FITNESS FOR PURPOSE, WHETHER
EXPRESS, IMPLIED, OR ARISING BY OPERATION OF LAW, TRADE
USAGE, OR COURSE OF DEALING ARE HEREBY DISCLAIMED.
NOTWITHSTANDING THE FOREGOING, THERE ARE NO WARRANTIES WHATSOEVER ON ITEMS BUILT OR ACQUIRED WHOLLY OR
PARTIALLY, TO BUYERS DESIGNS OR SPECIFICATIONS.
5. Limitation Of Remedy: SELLERS LIABILITY ARISING FROM OR IN
ANY WAY CONNECTED WITH THE ITEMS SOLD OR THIS CONTRACT
SHALL BE LIMITED EXCLUSIVELY TO REPAIR OR REPLACEMENT OF
THE ITEMS SOLD OR REFUND OF THE PURCHASE PRICE PAID BY
BUYER, AT SELLERS SOLE OPTION. IN NO EVENT SHALL SELLER
BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL
DAMAGES OF ANY KIND OR NATURE WHATSOEVER, INCLUDING
BUT NOT LIMITED TO LOST PROFITS ARISING FROM OR IN ANY WAY
CONNECTED WITH THIS AGREEMENT OR ITEMS SOLD HEREUNDER,
WHETHER ALLEGED TO ARISE FROM BREACH OF CONTRACT,
EXPRESS OR IMPLIED WARRANTY, OR IN TORT, INCLUDING WITHOUT LIMITATION, NEGLIGENCE, FAILURE TO WARN OR STRICT
LIABILITY.
6. Changes, Reschedules and Cancellations: Buyer may request to
modify the designs or specifications for the items sold hereunder as well
as the quantities and delivery dates thereof, or may request to cancel all
or part of this order, however, no such requested modification or
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unless accepted by Seller in a written amendment to this Agreement.
Acceptance of any such requested modification or cancellation shall be
at Sellers discretion, and shall be upon such terms and conditions as
Seller may require.
7. Special Tooling: A tooling charge may be imposed for any special
tooling, including without limitation, dies, fixtures, molds and patterns,
acquired to manufacture items sold pursuant to this contract. Such special
tooling shall be and remain Sellers property notwithstanding payment of
any charges by Buyer. In no event will Buyer acquire any interest in
apparatus belonging to Seller which is utilized in the manufacture of the
items sold hereunder, even if such apparatus has been specially
converted or adapted for such manufacture and notwithstanding any
charges paid by Buyer. Unless otherwise agreed, Seller shall have the
55


2745 Snapps Ferry Road
Greeneville, TN 37745 USA
Tel:
(423) 639-8151
FAX:
(423) 787-2418
www.parker.com/pumpmotor
Installation and Maintenance Instructions

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

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

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

assemble piston & cylinder sub-assembly to remainder
of brake securing with 6-off SHCS and washers (13 &
14). Torque tighten to 55 lbF.ft (75 Nm).
Note: The use of a suitable press (hydraulic or arbor)
pressing down on cylinder end face B will ease
assembly of the SHCS (13).
Note: If new friction plates have been assembled,
it is recommended that the friction faces are
bedded in to help ensure stable torque
performance.
INTRODUCTION
This manual is a step-by-step guide to assembly and disassembly of torque-hub units. It is designed for the customer or
shop mechanic who is repairing a particular model of torque-hub
final drive. Users of this manual should note that each part
mentioned is followed by an indentification number enclosed in
parentheses. These part numbers may be referred to in the Parts
List section of this manual and on the cross-sectional view of this
unit. A print of each tool discussed in this manual is shown in the
Tooling section. Users should familiarize themselves with the
procedures for roll and leak testing and bolt tightening and
torquing found on the following two pages before getting started.
This manual includes the following sections.
1. Roll and Leak Testing Procedures
2. Bolt Tightening and Torquing Procedures
3. Disassembly Procedures
4. Sub-Assembly Procedures
5. Main Assembly Procedure
6. Drawings of all Essential Tools
7. Parts List
8. Cross-Sectional View of the Unit
SAFETY
Standard safety practices should be followed during the

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

Torque-hub units should always be roll and leak tested before
disassembly and after assembly to make sure that the units gears
and sealants are working properly. The following information briefly
outlines what to look for when performing these tests.
THE ROLL TEST
The purpose of a roll test is to determine if the

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

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

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

tightening and torquing
in a bolt circle.
describe the proper procedure for

bolts or socket head cap screws
1. Tighten (but do not torque) bolt

A until snug.
2. Go to the opposite side of the bolt

circle and tighten bolt B until
equally snug.
3. Continue around the bolt circle

and tighten the remaining bolts.
4. Now use a torque wrench to apply

the specified torque to bolt A
5. Continue around the bolt circle

and apply an equal torque to the
remaining bolts.
III
MAIN DISASSEMBLY
1. Remove pipe plug (15) from cover(6)
and drain the oil from the unit.
2.
Roll test the unit in both
clockwise and counterclockwise
directions. Perform the same number
of turns in each direction as the
ratio of the unit. The ratio number is
the same as the last two digits in the
model number found on the ID tag of
the unit.
3. Leak test the unit at a pressure of

5 psi for 2-3 minutes.
4. Remove all 24 grade 8 bolts(16)

from cover(6).
5. Lift cover(6) off of hub(1G) and

remove O ring(5) from the counterbore in the cover. Discard the O
ring.
6. Remove small thrustwasher(7) from

the counterbore in the center hole in
cover(6).
7. Remove large thrust washer(14),

thrust bearing(13), and large thrust
washer(12) from the raised inside
circular edge of cover(6).
8. Remove input gear(8) from mesh

with the planet gears in first stage
carrier assembly(3).
9. Lift out first stage carrier

assembly(3).
10. Remove small thrust washer(9)

from the top of second stage sun
gear(11).
11. Remove thrust bearing carrier(10),

large thrust washer(14), thrust bearing(13), and large thrust washer(12)
from the counterbore of second stage
12. Remove second stage sun gear(11)

from mesh with second stage carrier
assembly(2).
13. Lift out ring gear(4).
14. Remove O ring(5) from the

counterbore in hub(1G) and discard.
15. Lift out second stage carrier

assembly(2) from mesh with output
shaft(1A).
16. Using retaining ring pliers,

remove retaining ring(1L) from groove
around the outside of output shaft
(1A).
CAUTION: Safety glasses should be
worn during this procedure.
17. With a screwdriver or chisel and

hammer, straighten out the tang on
lockwasher(1J) which has been bent
into the notch on locknut(1K).
18. Using an AN-18 locknut wrench

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

washer(1H) from output shaft(1A).
Discard the lockwasher.
20. Raise hub(1G) above your work

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

output shaft(lA).
22. Lift bearing cone(1F) out

hub(1G).
of
23. Using a soft punch and hammer,

remove bearing cups (1E) and (1C)
from hub(1G). Be very careful not to
strike the counterbores of the hub
where these cups are located when
using the punch.
24. Remove all four pipe plugs (1M),

(1N), and (1P) from hub(1G).
25. At this point the main disassembly

is complete.
FIRST STAGE CARRIER DISASSEMBLY
1. Locate dowel pin(3D) which holds

planes shaft(3E) in carrier housing
(3A).
2. Drive the dowel pin(3D) down into

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

carrier housing(3A). The four thrust
washers(3B) and planet gear(3F) will
slide off.
4. Using an alignment punch and

hammer, drive dowel pin(3D) out
through the end of the dowel pin
hole in planet shaft(3E) that it
originally went into.
5. Remove needle rollers(3C) from

inside planet gear(3F).
6. Repeat steps 1-5 to remove the two remaining planet gears.
7. At this point the first stage carrier disassembly is complete.
SECOND STAGE CARRIER DISASSEMBLY
1. Locate dowel pin(2G) which holds

planet shaft(2E) in carrier housing
(2A).
2. Drive dowel pin(2G) down into

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

carrier housing(2A). The four thrust
washers(2B) and planet gear(2F) will
slide off.
4. Using an alignment punch and

hammer, drive dowel pin(2G) out
through the end of the dowel pin
hole in planet shaft(2E) that it
originally went into.
5. Remove needle rollers(2C) and

spacer(2D)
from
inside
planes
gear(2f)
6. Repeat steps 1-5 to remove the two remaining planets gears.
7. At this point the second stage carrier disassembly is complete.
FIRST STAGE CARRIER SUB-ASSEMBLY
1. Apply grease to the inside of one

first stage carrier planes gear(3F).
2. Line the inside of planet gear

(3F) with 19 needle rollers(3C).
3.Stand first stage carrier housing(3A)

in an upright position.
4. Insert a planet shaft(3E) into

one of the planet shaft roles which
has a dowel pin hole on carrier
housing(3A). The end of the planet
shaft that does not have the dowel
pin hole should be inserted into the
carrier housing first.
NOTE: One end of the dowel pin hole on the planet shaft has a
chamfer or gradual slope. This end should be up to allow easy
alignment.
10
5. Place two thrust washers(3B) onto

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

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

two more thrust washers(3B) onto
planet shaft(3E).
8. Now insert planet shaft(3E)

through the opposite planet shaft
hole on carrier housing(3A).
9. Using an alignment puch or

similar tool, align the dowel pin
holes on carrier housing(3A) and
planet shaft (3E).
11
10. If you examine a dowel pin (3D)

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

two remaining first stage planes gears(3F).
l2. At this point the first stage carrier sub-assembly is complete.
12
SECOND STAGE CARRIER SUB-ASSEMBLY
1. Apply grease to the inside of one

second stage planet gear(2F).
2. Line one half of planet gear(2F)

with 18 needle rollers(2C).
3. Place one spacer(2D) inside

planet gear(2F) so that it rests on
top of the needle rollers (2C).
4. Line the remaining half of planet

gear(2F) with 18 needle rollers(2C).
13
5. Stand second stage carrier housing(2A) in an upright position.
6. Insert planet shaft(2E) into a

planet shaft hole that does not have
a dowel pin hole on carrier housing
(2A). The end of the planet shaft
with the dowel pin hole should be
inserted into the carrier housing
first.
NOTE: One end of the dowel pin hole on the planet shaft has a
chamfer or gradual slope. This end should be up to allow easy
alignment.
7. Place two thrust washers(2B) onto

the end of the planet shaft which
has been inserted through the planet
shaft hole.
8. Following the thrust washers,

place planet gear(2F), with needle
rollers, onto planes shaft(2E).
14
9. Following the planet gear, place

two more thrust washers(2b) unto
planet shaft(2E).
10. Now insert planet shaft(2E)

through the opposite planet shaft
hole on carrier housing(2A).
11. Using an alignment punch or

similar tool, align the dowel pin
holes on the carrier housing and
planet shaft.
12. If you examine a dowel pin(2G)

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

two remaining second stage planet gears(2F).
14. At this point the second stage carrier sub-assembly is

complete.
15
HUB-SHAFT SUB-ASSEMBLY
1. Apply a light coat of NeverSeize to the four hub pipe plugs

(1M), (1N), and (1P).
Note: Pipe plug(1P) is a magnetic
plug.
2. With hub(lG) standing on its

large diameter end, tighten pipe
plugs(1M) into the two pipe plug
holes nearest the small diameter end
of hub(1g).
NOTE: Notice that pipe plugs(lM) are
much smaller than pipe plugs (1N)
and (1P).
3. Turn hub(1G) over so that it

rests on its small diameter end and
the two pipe plug holes nearest the
hubs large diameter and are facing
you. Tighten magnetic pipe plug(1P)
into the right-hand pipe plug hole.
4. Mark the location of magnetic

pipe plug(1P) so that it may be
aligned with the pipe plug hole in
cover(6) in a later step.
16
5. Install pipe plug(1N) into the left-hand pipe plug hole

nearest the large diameter end of hub (1G).
6. With hub(1G) still standing on

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

rests on its small diameter end.
Press bearing cup(1E) down into
hub(lG) using a bearing cup pressing
fixture (tool no. T-130717).
NOTE: Make sure that the cup sits
square with the counterbore of the
hub before pressing.
8. Spray the
cone(1D) with oil.
inside
of
bearing
9. Press bearing cone(1D) onto output shaft(1A) using a bearing cone

pressing fixture (tool no.T-158049).
17
10. With small diameter end down,

lower hub(1G) onto output shaft(1A).
11. Spray the

cone(1F) with oil.
inside
of
bearing
12. Press bearing cone(1F) onto

output shaft(1A) using a bearing
cone pressing fixture (tool no. T146588). Reduce the pressure applied
to the bearing cone and press the
cone again. This time rotate the
hub in both clockwise and counterclockwise directions while pressing.
Stop pressing when the hub starts to
resist the rotation.
13. Now measure the initial rolling torque of hub(1G). To do

this, follow steps a-d.
a) Tighten a bolt into one of the

bolt holes on the hub. The bolt used
should be one that fits the hole.
18
b) Place a torque wrench on the bolt so that the arm of the

wrench lines up on a tangent to the circumference of the hub as
shown in figure 1.
c) Keeping the wrench in this

position at all times, use the arm
of the wrench to guide the hub
around in one rotation.
d) Read the gauge on the torque wrench. The initial rolling

torque should be 25-30 in.-lbs. Measure the rolling torque
several times to insure an accurate reading.
NOTE: If the initial rolling torque is less than 25 in.-lbs.,

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

output shaft(1A).
19
Rolling Torque Procedure
THE CORRECT READING CAN ONLY BE MADE IF THE

TORQUE WRENCH IS PULLED SLOWLY (APPROX. 3.5 R.P.M.)
AND SMOOTHLY TOWARDS YOU.
Figure 1.
20
15. Place lockwasher(1J) onto output

shaft(1A).
NOTE: Notice that lockwasher(1J) has
tangs and tanged washer(1H) does
not.
16. Spray the inside of locknut(1K)

and the exposed sides of output
shaft(1A) with Locquic Primer T.
Allow two minutes drying time.
17. Apply Loctite 277 Adhesive/

Sealant to the second screwthread
from the bottom of locknut(1K).
NOTE: The bottom of locknut(1K) has
a chamfered or inward sloping edge.
NOTE: Loctite 277 is an anaerobic adhesive. Once it has been

removed from air, it sets. Therefore, once the locknut has been
placed on the output shaft, it must be torqued immediately or the
adhesive will make it difficult to turn.
18. Place locknut(1K) onto output

shaft(1A) and screw into place.
21
19. Using an AN-18 locknut wrench

(tool no. T-156766) and a torque
wrench, apply 225 ft.-lbs. of torque
to locknut(1K).
NOTE: One tang on lockwasher(1J) must line up directly with one

notch on locknut(1K). If one tang does not line up with a
locknut notch, apply sufficient increased torque to the locknut
until it does. Never loosen the locknut.
20. Measure
of hub(1G)
described in
final rolling
35-60 in.-lbs.
the final rolling torque

using the same manner
steps 13a - 13d. The
torque should measure
NOTE: Remove the bolt from the hub.
21. Bend the aligned tang on

lockwasher(1J) up into the notch on
locknut(1K).
22. Using a center punch and hammer,

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

rests on its large diameter end.
Spray oil on all exposed surfaces
inside the hub while turning output
shaft(1A).
2. Spray the inside of seal(1B) with

oil.
NOTE: The open face of the seal may
have a waved surface. This is an
intentional design used to keep dirt
out.
3. Press seal(1B) into the small

diameter end of hub (1G) using a seal
pressing fixture (tool no.T-156799).
4. Turn hub(1G) over once again so

that it rests on its small diameter
end. Using retaining ring pliers,
insert retaining ring(1L) into the
groove on output shaft(1A).
CAUTION: Saftey glasses should be
worn during this procedure.
23
5. Place second stage carrier assembly(2), with spline connections down,

into hub(1G) so that the carriers
spline connections mesh with the
spline connections on output shaft
(1A).
6. Spray oil on all exposed surfaces

inside hub(1G).
7. Grease O ring(5).
8. Place O ring(5) into the

counterbore of hub(1G). Make sure
that the counterbore is oil free
before installing O ring.
CAUTION: Beware of sharp edges and
burrs in the counterbore while installing the O ring.
NOTE: O rings may be stretched to fit the counterbore. If an

O ring has been stretched too much, simply squeeze the O ring
together bit by bit as you place it around the counterbore. It
can be made to fit exactly.
24
9. Spary oil on the inside of ring

gear(4).
10. Place ring gear(4) with small

diameter end down, into hub(lG) so
that it fits over second stage
11. Place second stage sun gear(11),

with large diameter end down, into
mesh with the planet gears of the
second stage carrier assembly(2).
l2. Place large thrust washer(14),

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

(10), with small diameter end down,
into the counterbore of second stage
carrier assembly(2). It should fit
over the thrust bearing set(12, 13,
14) described in step 12.
25
14.
Place
first
stage
carrier
assembly(3), with spline connections
down, into mesh with the second
stage sun
gear(ll) and the ring
gear(4).
15. Place small thrust washer(9) on

top of second stage sun gear(ll).
16. Place input gear(8), with small

diameter end down, into mesh with
the planet gears of first stage
carrier assembly(3). The input gear
should be centered on the small
thrust washer(9).
17. Set cover(6) down on its small diameter end.
18. Grease one side of large thrust

washer(12), thrust bearing(13), and
large thrust washer(14) and place
them greased side down in that order
over the raised inside circular edge
of cover(6).
NOTE: Notice that thrust washer(14)
is much thicker that thrust washer
(12).
26
19. Grease small thrust washer(7)

and place it in the counterbore of
the center hole in cover(6).
20. Grease O ring(5) and place it

around the counterbore in cover(6).
CAUTION: Beware of sharp edges and
stalling the O ring.
NOTE: O rings may be stretched to fit the counterbore. If an

O ring has been stretched too much, simply squeeze the O ring
together bit by bit as you place it around the counterbore. It
can be made to fit exactly.
21. Place cover(6), with large

diameter end down, on top of ring
gear(4) so that the covers pipe
plug hole aligns with the magnetic
pipe plug hole in hub(lG) according
to figure 2.
27
Pipe Plug Timing
This figure shows the most common

pipe plug timing for this series.
Pipe plug timings may vary among
units with different model numbers.
Refer to an original assembly print
for your particular unit to determine its correct pipe plug timing.
Figure 2.
22. Place the 24 grade 8

into cover(6) and tighten.
bolts(16)
23. Using a torque wrench, apply 3545 ft.-lbs of torque to each grade
8 bolt (16).
28
24. Apply a light coat of NeverSeize to pipe plug(15).
25. Tighthen pipe plug(15) into the

pipe plug hole in cover(6).
26. Roll test the unit in both

clockwise
and
counterclockwise
directions. Perform the same number
of turns in each direction as the
ratio of the unit. The ratio number
is the same as the last two digits
in the model number found on the ID
tag of the unit.
27. Leak test the unit at a pressure

of 5 psi for 2-3 minutes.
28. At this point the main assembly

complete.
29
TOOLING
The following specialized tools are used in the assembly of
this unit. The tool diagrams included in this manual are intended
for the customer who may wish to have a tool made. All tools must
be made from mild steel. All dimensions are given in inches.
OPTIONAL: In order to improve tool life, tools may be carborized
and hardened. If this is done, however, the tools must be ground
on all surfaces labeled with a G on the tool diagram.
1. TOOL NO. T-130717

BEARING CUP PRESSING FIXTURE for CUP(1E)
2. TOOL NO. T-156792
BEARING CUP PRESSING FIXTURE for CUP(1C)
3. TOOL NO. T-158049
BEARING CONE PRESSING FIXTURE for CONE(1D)
4. TOOL NO. T-146588
BEARING CONE PRESSING FIXTURE for CONE(1F)
5. TOOL NO. T-156766
AN-18 LOCKNUT WRENCH
6. TOOL NO. T-156799
SEAL PRESSING FIXTURE
30
31
T-130717
SCALE: 3/4 ONE PIECE
BEARING CUP PRESSING FIXTURE
for CUP(1E)
32
T-156792
SCALE: 3/4
BEARING CUP PRESSING FIXTURE
for CUP(1C)
33
T-158049
BEARING CONE PRESSING FIXTURE
for CONE(1D)
34
T-146588
SCALE: full ONE PIECE
BEARING CONE PRESSING FIXTURE
for CONE(1F)
35
T-156766
AN-18 LOCKNUT WRENCH
USE 3/4 in. DRIVE SOCKET
36
T-156799
SEAL PRESSING FIXTURE
SCALE: 2/3
PARTS LIST
ITEM
QUANTITY
DESCRIPTION
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
hub-spindle sub-assembly
output shaft
seal
bearing cup
bearing cone
bearing cup
bearing cone
hub
tanged washer
lockwasher
locknut
retaining ring
pipe plug
pipe plug
magnetic pipe plug
1
12
108
3
3
3
3
second stage carrier sub-assembly

second stage carrier
thrust washer
needle roller
spacer
planet shaft
planet gear
dowel pin
1
12
57
3
3
3
first stage carrier sub-assembly

1 first stage carrier
thrust washer
needle roller
dowel pin
planet shaft
planet gear
1A
1B
1C
1D
1E
1F
1G
1H
1J
1K
1L
1M
1N
1P
2
1
2A
2B
2C
2D
2E
2F
2G
1
3A
3B
3C
3D
3E
3F
4
5
6
7
8
9
ring gear
O ring
cover
thrust washer
input gear
thrust washer
1
2
1
1
1
1
37
ITEM
QUANTITY
DESCRIPTION
10
11
12
13
14
15
16
17
18
1
1
2
2
2
1
24
4
1
thrust bearing carrier

second stage sun gear
thrust washer
thrust bearing
thrust washer
pipe plug
bolt
drive screw
ID plate
38
39
CROSS-SECTIONAL VIEW of S6A
Instructions:
Change of Rotation
and Seal Replacement
13
(PGP500 Series)
12
11
4
5
6
13
9
12
10
6
5
4
3
2
8
1
Item
13
12
11
10
9
8
7
6
5
4
3
2
1
Quantity
4
4
1
1
2
1
1
2
2
2
2
1
1
Description
Capscrew
Washer
Housing, Pec
Housing, Gear
Sea, O-R
Gear, driven
Gear, drive
Thrblk
Channel Seal
Seal, bk-up
Pin, dowel
Housing, sec
Lip seal
3
13
CAPSCREW GR 8
Note: Before disassembling ensure that the unit, bench and tools are thoroughly clean.
Disassembly Instructions:
1. Where applicable, remove the drive coupling from the drive shaft using a suitable puller. The coupling
must not be levered or hammered as this may cause internal pump damage.
2. If the pump has a keyed shaft, remove the key from the shaft. Lightly stone any burrs that may be on
the shaft to prevent any damage to the seal during disassembly.
3. Clamp the pump in a vise using the mounting flange (2), with the drive shaft pointing down. Do not
clamp on the machined pilot ring.
4. Scribe a line across the shaft end cover (2), gear housing (10) and port end cover (11). This will
ensure proper alignment during reassembly.
5. Remove all the mounting bolts (13) and washers (12) from the assembly.
6. Remove the rear port end cover (11).
7. Lift the gear housing (10) off of the shaft end cover (2), tapping the housing with a soft mallet, if necessary.
8. Remove the rear bushing block (6) noting the orientation of the channel seal (5).
9. Carefully remove the gears by pushing up on the drive shaft (7). Remove the front bushing block (6)
noting its orientation.
Change of Rotation Instructions:

These instructions are intended for use in changing the rotation of a single section PGP500 series gear pump.
Reassembly Instructions:
1. Rotate front bushing block (6) 180 from original position and place on shaft end cover (2). Make sure
the backup seals (4) and channel seals (5) are seated properly.
Gear Pump Division
1775 Logan Avenue
Youngstown, Ohio 44501
Tel: (330) 746-8011 Fax: (330) 746-1148
http://www.parker.com/gearpump
2. Seat O-rings (9) in the machined groove and rotate housing (10) 180 around the shaft axis and
place onto shaft end cover (2). Readjust location of dowel pins (3) if pulled out at disassembly.
Note from Disassembly Step 4 that the line on the housing (10) and cover (2) should now be on
opposite sides.
3. Slide the drive shaft gear (7) through the gear housing, bushing, and shaft seal. Be careful not to
damage the shaft seal. Slide the driven gear (8) through the gear housing and into the bushing.
4. Rotate rear bushing block (6) 180 from original position and place on gears. Make sure the
backup seals (4) and channel seals (5) are seated properly.
5. From its original position, rotate the port end cover (11) 180 around the shaft axis and position it
over the gear housing.
6. Replace the washers and bolts into the unit. Torque bolts in a diagonal pattern. Dry assembly
torques are given in Table 1. Do not over torque.
7. Rotate drive shaft with a small wrench to check for any binding.
Table 1: PGP/PGM500 series assembly torques

SERIES
PGP/PGM505
PGP/PGM511
PGP/PGM517
ASSEMBLY
TORQUE
300 in-lbs(25 ft-lbs)
420 in-lbs (35 ft-lbs)
1000 in-lbs (83 ft-lbs)
Seal Replacement Instructions:

These instructions are intended for use in changing the seals of a single PGP/PGM500 series gear pump
or motor. Note the shape and orientation of all seals before and during removal.
1. If shaft end cover has a snap ring and outboard bearing, carefully remove. Insert a small diameter punch or screwdriver from inside the cover into the shaft seal opening. Gently tap to drive
out the shaft seal.
2. Press the replacement shaft seal (1) squarely into the seal recess in the shaft end cover until it
bottoms out. Lip seal garter spring faces in toward unit. Reinstall snap ring and bearing if applicable. Remount cover (2) in the vise.
3. Remove old plastic and rubber seals from the thrust blocks (6) and replace with new seals (4 &
5). Note seal orientation. Grease will help hold the seals in place.
4. Remove section seals (9) from housing (10) and replace with new o-rings. Light grease will help
hold the seals in place.
5. Replace the front thrust block (6) on the shaft end cover (2) with seals facing down. For pumps,
orient so middle of seal points to low pressure (inlet) side.
6. Position housing (10) on the cover (2) making sure the lines from Disassembly Step 4 match up
(unless changing rotation). Tap in place with a soft mallet.
7. Replace the drive gear (7) and driven gear (8). If included in the seal kit, put the protective sleeve
over the drive shaft before pushing through the shaft seal.
8. Replace the rear thrust block (6), seals facing up, with the middle of the seal pointing to the low
pressure side.
9. Reinstall the port end cover (11) aligning the markings with the housing and shaft end cover.
10. Replace the four bolts and washers. Torque in a diagonal pattern according to the values
in Table 1.
BULLETIN NO.GZ-MS-A066-3000E
MAG-170VP-3000E-1
SERVICE MANUAL
KAYABA INDUSTRY CO. LTD / KYB AMERICA LLC
START-UP
try again. Do not disassemble the Plunger Assy.

Remove the Relief Valve Assy (102-7), loosening the
Plug (102-7-6). Do not loosen the Nut (102-7-16) and
Set Screw (102-7-15). The setting pressure is changed
by loosening the Nut and Set Screw. The Poppet Seat
(102-7-3) will be remained in the Base Plate. Remove
the Poppet Seat.
(d) Remove the Plugs (102-17) and the Spring (102-13).
While turning, pull the Spool (102-9) out. If difficulty is
encountered, Tap the end of the Spool and insert it. Be
sure the Spool slides smoothly, then try again.
(e) Do not loosen the Plugs (102-8) and the Orifices
(102-23) (102-22) if it is not necessary.
(f) Loosen the Socket Head Bolts (300) evenly and pull the
assembly of the Case (101) and Base Plate (102-1) out
of the Flange (210). If difficulty is encountered, tap the
top of the Base Plate (102-1) and insert it, then try
again.
(g) Position the assembly of the Case and Base Plate Assy
with shaft down. Loosen the Socket Head Bolts (120)
evenly and remove the Base Plate (102-1) away with
the caution not to have the Pins (128) stick.
(h) Remove the Valve Plate (105), the Springs (129) (149),
the O-Ring (122) (133) and the Pin (118) (128). Care
must be taken during the process not damage the Valve
Plate.
2. Brake Piston
(a) Blow compressed air to the oil passage of the brake to
remove the Brake Piston (125) from the Case. Pay full
attention the Brake Piston may be ejected out.
(b) Remove the O-Rings (130) (131) from the Brake Piston.
Remove the Disk Plate (127) and Friction Plate (126).
3. Cylinder Block
(a) Pull the Cylinder Block Assembly (104) (106) (107)
(108) (114) (115) (116) (117) (119) out by holding the
Retainer Plate (107) and the Cylinder Block. Care must
be taken during the process not damage the Piston
Shoe and Cylinder Block.
(b) Mark the Piston Assy and Cylinder Block to identify the
each position. Remove the Piston Assy (106) and
Retainer Plate (107) from the Cylinder Block (104).
(c) Remove the Retainer Holder (108) and Pins (119).
(d) Press the Spring, using the press machine. Use a Snap
Ring Pliers to remove the Snap Ring (114). Remove the
Collar (115) (117) and the Spring (116) from the
Cylinder Block.
4.
Remove the Swash Plate (109).
5.
Remove the Steel Balls (110), the Piston Assy (111)
and the Spring (139) from the Case. The Steel Ball may
be come with Swash Plate.
6.
Remove the Shaft (103), the Ball Bearing (112)and the
Oil Seal (121).
7.
Gear Box
(a) Remove the Plugs(226) and Drain the lubrication oil in
the Gear Box.
(b) Remove the Socket Head Bolts (208) and the Cover
(224). Tap the Cover using plastic hammer to remove
the Cover, because the Cover is sealed by liquid gasket.
(c) Remove the Thrust Plate(s) (223).
(d) Remove the Drive Gear (204) and the Holder A S/A
(201).
(e) Remove the Thrust Plate (205) and the Sun Gear B
(c)
Fill the Gear Box with lubricating oil, before and until the oil
flows out of oil check port on the Cover. After confirming the
sufficient oil level, tighten each plugs of the port.
Air and water must be purged from the hydraulic system,
otherwise the hydraulic components will be subject to failure
from cavitation or lack of lubrication. The motor may be
purged by operating for a while under no load with low speed.
Check also that no air bubbles are present in the reservoir
before beginning the operation.
Make sure all connections are tight.
PERIODIC MAINTENANCE
REPLACE SEALS
Replace all seals in the motor section, if the accumulated
operation period with the fluid temperature over 80 (176F)
is reached 100 hours.
Replace all seals in the Gear Box, if the accumulated
operation period with the oil temperature over 90 (194F) is
reached 100 hours.
HYDRAULIC FUID
Initial Replacement
Visual Inspection
Performance Inspection
500 Hr.
Every 500 Hr.
Every 1000 Hr.
HYDRAULIC FILTER
Initial Replacement
Periodic Replacement
50 Hr.
Every 250 Hr.
LUBRICATING OIL
Initial Replacement
Performance Inspection
Periodic Replacement
100 ~ 250 Hr.

Every 1000 Hr.
Every 1000 ~ 1500 Hr.
MOTOR SECTION
Internal Inspection and Seals Replacement
Every 1000 Hr.
Brake Disk Replacement
Every 300,000 cycle
SERVICE INFORMATION
PREPARATION
Before removing the motor from the installation, drain all oil
inside, then cover the oil port area to prevent foreign particles
from entering the motor. Before disassembling the motor,
clean outside of the motor thoroughly. During disassembling,
warn the parts to protect from damage.
DISASSEMBLY PROCEDURE
1. Base Plate
(a) Position the motor with the piston motor side up. Loosen
the Socket Head Bolts (102-6-4) evenly. Remove the
Flange (102-6-1), Spring Seat (102-5), Spring (102-4)
and Spring Seat (102-3).
(b) While turning, pull the Plunger Assy (102-2) out. If
difficulty is encountered, tap the end of the Plunger and
insert it. Be sure the Plunger slides smoothly and then
06/25/1999
MAG-170VP-3000E-1
SERVICE MANUAL

(f)
(i)
(g)
(h)
(i)
(j)
(k)
(l)
(206).
Remove the Holder B S/A (202) and the Sun Gear C
(208).
Loosen the Socket Head Bolts (221) evenly and remove
the Ring Gear (219) with the caution not to have the
Pins (222) stick.
Loosen the Socket Head Bolts (216) (217) and remove
the Plate (218). Using a press, remove the Holder C S/A
(203) with the caution not to have the Pins (215) stick.
Remove the Shim (214).
Remove the Coupling (600).
Press the Flange (210) out of the Housing (213).
Using (-) screwdriver remove the Floating Seal (211)
from the Housing.
Press the Angular Bearings (212) out of the Housing.
Using (-) screwdriver remove the another Floating Seal
(211) from the Flange.
Pins project from the Flange by 26.5 27.5 mm.

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

Sufficient rust prevention is necessary to store the parts.
ASSEMBLY PROCEDURE
Holder C
S/A (203)
Ring Gear
(219)
Thrust Plate ( 223 )

20941-62305
20941-62306
20941-62307
20941-62308
20941-62309
table-1
(w) Degrease the contact surface of the Ring Gear (219)

and the Cover (224). Apply uniformly the liquid gasket,
Three Bond 211 and then put the Cover onto the Ring
Gear. Tighten the Socket Head Bolts (225).
(x) Tighten the Plugs (226) using Teflon tape.
(y) Position the Gear Box with the piston motor side up.
Degrease the thread surface of the Socket Head Bolts
(217) and thread hole of the Flange (210). Apply
Locktite No.217 on the thread surface of the Socket
Head bolts. Put the Plates (218) into the Flange (210)
and tighten the Socket Head Bolts (217).
(z) Ensure the Pin (601) is completely inserted into the
Coupling (600) and put the coupling onto the spline
shaft of the Drive Gear (204).
t
(k)
Gap ( Hr )
1.74 to 1.21
1.20 to 0.67
0.66 to 0.04
0.03 to -0.16
-0.17 to 0.41
t : Thickness of the
Shim(s)
H
(i)
(j)
Holder A
S/A (201)
t > h - H
Shim(s)
(214)
Flange
(210)
Hr
All parts must be thoroughly cleared and ensured there is no

dust, damage or scratch prior to assembly. Seals and
bearings must be replaced with new one.
1. Gear Box
(a) Grease fully the Floating seals (211). Put the one of
Floating Seal (211) into the Flange (210).
(b) Put the other Floating Seal on the Floating seal already
set on the Flange. Ensure the concentricity of these
Floating Seals.
(c) Press the inner race of the Angular Bearing (212) into
the Flange (210).
(d) Press the outer races of both Angular Bearings into the
Housing (213) from both sides.
(e) Put the Housing (213) on the Flange (210) quietly.
(f) Press the inner race of the Angular Bearing remaining
into the Flange (210).
(g) Press the top of the inner race of the Angular Bearing
(212) already installed into the Flange (210) with even
thrust force of 3000kgf. While pressing, measure the
gap ( H ).
(h) Measure the gap ( h ) on the bottom surface of the
Holder C S/A (203).
Housing
(213)
Calculate the shim thickness required ( t ).

The Shim(s) (214) may be combined in order to assure
that Height of the Shim(s) ( t ) is slightly greater than
h - H.
Press the Pins (215) into the Flange (210) so that the
06/25/1999
MAG-170VP-3000E-1
SERVICE MANUAL

2.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
3.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
Plunger Assy. Ensure the O-Ring (102-6-2) is put into

the groove on the Cap Assy (102-6). Put both Caps
(102-6) to the Base Plate (102) and tighten the Socket
Head Bolts (102-6-4).
Motor Section
Apply grease on the Oil Seal (121). Press into the Case
(101). Ensure the Oil Seal was completely installed.
Place the Springs (139) into the bores at the bottom of
the Case (101). Apply grease on the sliding surfaces of
the Piston Assys (111) and insert into the bores.
Press the Ball Bearing (112) onto the Shaft (103). Insert
the Shaft into the Case (101). Ensure the Shaft rotates
smoothly.
Apply working fluid on the Steel Balls (110) and the
spherical hollows at the bottom of the Case (101). Place
the Steel Balls into the hollows and the Swash Plate
(109) into the Case (101).
Place the Spring Seat (115), the Spring (116) and the
Collar (117) into the Cylinder Block (104). Press the
Spring and install the Snap Ring (114).
Apply grease on the Pins (119) and insert the Pins into
the Cylinder Block (104). Place the Retainer Holder
(108) onto the Cylinder Block.
Put all the Piston Assy (106) into the Retainer Plate
(107) from the flat surface of the Retainer Plate.
Apply the hydraulic fluid in the bores of the Cylinder
Block (104) and on the spherical surface of the Retainer
Holder (108). Insert the Piston Assys into the Cylinder
Block.
Apply the hydraulic fluid on the sliding surface of the
Swash Plate (109) and the sliding surfaces of the shoes
of the Piston Assys. Insert the Cylinder Block Assembly
onto the Shaft (103).
Submerge the Disk Plate (127) in the hydraulic fluid
prior to the assembly. Place the Disk Plates and the
Friction Plate (126) into the Case (101).
Fit the D-Rings (130) (131) into the grooves of the Brake
Piston (125) and apply grease on the sliding surface.
Insert the Brake Piston into the Case so that the holes
for the pins on the Brake Piston and Case align.
Put the Springs (141) and (129) onto the Brake Piston.
Base Plate
Press the Ball Bearing (113) into the Base Plate (102).
Insert the Pin (118) into the Valve Plate (105).
Apply grease to the back of the Valve Plate. Place the
Valve Plate onto the Base Plate with the bronze color
side up.
Apply grease on the O-Ring (122) and place it onto the
Case (101).
Place the O-Rings (133) onto the Case (101) without
grease. Insert the Pins (128) into the Base Plate (102)
with tapered side up.
Place the Base Plate (102) onto the Case (101) with
caution that any parts under the Base Plate should not
drop. Tighten the Socket Head Bolts (120) and (300).
Insert the Spool (102-9) ,Spring (102-13) and Spring
Guide (102-16) into the Base Plate(102). Ensure the
O-Rings (102-15) are installed into the Plugs (102-14)
and (102-17), tighten the Plugs into the Base Plate.
Make sure that there is the Poppet Seat (102-7-3) at the
top of the Relief Valve. Apply grease onto the O-Rings
of the Relief Valve. Insert the Relief Valve Assy (102-7)
into the Base Plate (102) and Tighten.
Insert the Plunger Assy (102-2) into the Base Plate
(102). Place the Spring Seat (102-3), Spring (102-4),
and another Spring Seat (102-5) onto each side of
06/25/1999
MAG-170VP-3000E-1
SERVICE MANUAL
CRITERION REPLACEMENT
Replace parts in the following criterion when disassembling the motor.
Handle each of parts with deliberation and take care not to damage them.
Replace all seals when disassembling the motor, even though no damage is found on them.
Hydraulic Motor Section

Item & Check Point
Allowable Limit
Piston Assy (106)

(a) Deep score or roughness on the shoe.
(b) Deep score or roughness on the reciprocating potion.
(c) Large clearance between the Piston and Cylinder Block.
(d) Play on the shoe ball portion.
Cylinder Block (104)
(a) Deep score or roughness on the sliding portion.
(b) Deep score or roughness inside bore.
(c) Large clearance between the Piston.
(d) Large clearance between the Shaft spline.
Valve Plate (105)
(a) Roughness of the sliding portion or deep score caused by
serious damage, seizure and partial wear.
Retainer Plate (107)
Retainer Holder (108)
Swash Plate (109)
(b) Deep score or roughness on the Steel Ball portion.
(c) Depth of the Steel Ball portion.
Shaft (103)
(a) Deep lip mark, roughness or serious damage on the sliding
portion for Oil Seal.
(b) Excessive wear or breakage on the spline
(c) Large clearance between the Cylinder Block spline hole.
(d) Large clearance between the Coupling spline hole.
Brake Piston (125)
(a) Dimension
(b) Roughness or serious damage on the sliding portion.
Disk Plate (127)
(a) Dimension
(b) Serious damage or peeling.
Ball Bearing (112), (113)
(a) Serious damage on the races and Balls.
(b) Discontinuous rotation
Piston Assy (111)
(a) Deep score or roughness on the shoe.
(b) Deep score or roughness on the reciprocating potion.
(c) Large clearance between the Piston and Flange Holder.
(d) Play on the shoe ball portion.
Plunger Assy (102-2)
(a) Serious damage, roughness or deep score.
(b) Large clearance between the Plunger and bore.
Base Plate (102)
(a) Serious damage, roughness or deep score on the bore.
Spool (102-9)
(a) Serious damage, roughness or deep score.
(b) Large clearance between the Spool and bore.
Relief Valve Assy (102-7)
(a) Roughness or serious damage on the Free Piston sliding
Parts to be Replaced
Cylinder Block Kit (B6)
0.8a
1.2a
0.060mm
0.40mm
Cylinder Block Kit (B6)
0.8a
1.6a
0.060mm
38.749(pin dia.3.333)
Valve Plate (105)
0.8a
<0.02mm(scoring depth)
Retainer Plate (107)
Retainer Holder (108)
0.8a
0.8a
1.6a
14.5mm
Swash Plate (109)

Steel Ball (110) if it is necessary.
Shaft (103)
1.6a
47.380(pin dia.3.000
30.498(pin dia.3.33)
Brake Kit (125)
45. 7mm (Height)
2.5a
Brake Kit (127)
3.2 (Thickness)
Ball Bearing (112), (113)
Case Kit (B7)

1.6a
1.2a
0.040mm
1.0mm
0.8a
0.060mm
0.8a
Base Plate Kit (B5)
Base Plate Kit (B5)

Base Plate Kit (B5)
0.8a
0.060mm
Relief Valve Assy (B4)
06/25/1999
MAG-170VP-3000E-1
SERVICE MANUAL

portion or the Poppet seating portion.
06/25/1999
MAG-170VP-3000E-1
SERVICE MANUAL
06/25/1999
MAG-170VP-3000E-1
SERVICE MANUAL
06/25/1999
MAG-170VP-3000E-1
SERVICE MANUAL
06/25/1999
FKB Air Cleaner

Smaller, Lightweight Alternative Two-Stage Air Cleaner
Designed for horizontal installation
MEDIUM DUST
The FKB family of two-stage

air cleaners for medium dust
conditions.
Compared to other air cleaner
styles, this new air cleaner family
delivers the performance of
competitive larger air cleaners in a
compact, rugged design.
With a heavy-duty plastic
construction and non-metal filters,
the air cleaner is lighter, more
efficient and easier to install and
replace than competing products.
Another key design feature is the
built-in mounting brackets. There's
no need for additional mounting
support.
The two stage design features a
built-in pre-cleaner that separates
up to 85% of airborne contaminants.
Mann & Hummel
Donaldson FKB05
Fleetguard/Nelson
FKB air cleaners are smaller in diameter compared to competitive brands with similar airflow.
The FKBs plastic housing and

durable construction enables its
installation in all types of operating
environments and temperature
ranges from -40 to 82C, operating
in medium-dust conditions with
engine air flow from 70 to 360 cfm.
FKB air cleaners effectively reduce

contaminants flowing into the air
intake system, provide a high level
of engine protection from harmful
contaminants and increase engine
performance and fuel efficiency.
The air cleaner models ship with
both the primary and safety filters.
FKB08
FKB06
FKB05
FKB04
Donaldson FKB air cleaners are protected internationally by patents,
trademarks, and design registrations, both issued and pending.
40
Engine Air Cleaners, Accessories & Service Parts
www.donaldson.com/aircleaners
FKB Air Cleaner

Built-in Mounting Brackets and Filter Indicator Port
Easy to service with non-metal filters
Applications
Inlet
MEDIUM DUST
Off-road equipment operating in

medium-dust conditions with engine
airflow range of 70 to 360 cfm
(2 to 10.3 m3/min)
Installs horizontally. Mounting the
air cleaner directly to the engine is
not recommended; excessive engine
vibration can cause premature air
cleaner structural failure
Outlet
Sustained temperature tolerance:

-40 to 180F / -40 to 82C. Do not
install next to components that
exceed the maximum temperature
(180F / 82C); like a turbocharger,
muffler, exhaust pipe or other high
temperature component
Features
Smaller in diameter compared to

competitive brands with similar
airflow
Filter changeout is a snap

with minimal service
clearance required
Improved handling and maintenance:

lighter and smaller, changing filters is
a snap

Product design includes:

- primary filter
- safety filter
- filter service indicator port
Improved filter disposal ease: no

metal
Picture of the B080074 filters

next to the B045008 model
filters - each set is shipped
with the air cleaner.
Cover latch position allows for

minimum service clearance and
eases filter service
Mounting brackets built-in to air
cleaner body eliminating need for
mounting bands
41
FKB Air Cleaner
MEDIUM DUST
When specing an
Air Cleaner . . .
Initial Airflow Restriction

CFM
6" H2O 8" H2O 10" H2O
Determine the airflow requirements of your

engine, then find the corresponding cfm
airflow in the table at right. The restriction
numbers (shown in inches of water)
indicate the approximate initial restriction
of each model air cleaner at that cfm. If
there are two air cleaner models that fit
your parameters, choosing the one with the
lowest restriction will provide longest filter
service life. When calculating total initial
restriction of the entire air intake system,
include the restriction caused by ducting,
elbows, pre-cleaners, etc.
70
116
155
265
84
137
185
315
95
154
207
360
Airflow Pattern B
Air Cleaner
Model
Air in the side, out the end
B045008
B055006
B065045
B080074
FKB Specification Illustrations
Side View
Cover End View for B04, B05, and B06
Cover End View -B080074
D
G
I
B
JJ
F
A
M8 X 1.25
(2 - B04,B05 and B06)
M8 X 1.25
(4 - B080074)
FKB Specifications

Air Cleaner
Models
Body
Dia.
(A)
Inlet
Dia.
(B)
Outlet
Dia.
(C)
Housing Inlet
Length Height
(D)
(E)
Outlet
Length
(F)
Inlet
Center Service
Restr.
Mounting
Loca-
Line to Clear.
Tap
Bracket
tion (G) Valve (H) (I)
Weight Loc. (J) Height (K)
B045008

B055006

B065045

B080074

5.22"
133mm
5.97"
152mm
7.09"
180mm
8.95"
227mm
2.00"
51mm
2.50"
64mm
3.00"
76mm
4.00"
102mm
2.00"
51mm
2.50"
64mm
3.00"
76mm
4.00"
102mm
13.46"
342mm
15.89"
404mm
16.06"
408mm
16.75"
425mm
2.83"
72mm
2.88"
73mm
2.87"
73mm
2.40"
61mm
1.60"
41mm
1.93"
49mm
2.07"
53mm
2.68"
68mm
42
3.88"
99mm
3.88"
99mm
4.72"
120mm
5.50"
140mm
6.18"
157mm
6.18"
157mm
7.41"
188mm
7.78"
198mm
7.44"
189mm
9.61"
244mm
9.50"
241mm
14.76"
375mm
2.1 lb
1.0 kg
3.2 lb
1.4 kg
3.7 lb
1.7 kg
5.52 lb
2.5 kg
2.02"
52mm
2.05"
52mm
2.05"
52mm
1.57"
40mm
2.82"
72mm
3.03"
77mm
3.54"
90mm
4.33"
110mm
FKB Air Cleaner

Filter Service Indicator Port
Air Inlet
Plastic Housing
Service Cover
Primary Filter
Safety Filter inside
Cover latch position requires

minimum space requirement for
filter service
Vacuator Valve
Built-in
Mounting
Bracket
Safety Filter
FKB Service Parts
B045008
B065045
cover.................................................. P606497
filter, primary..................................... P604457
filter, safety........................................ P603729
Vacuator Valve.............................. P158914
cover.................................................. P608592
filter, primary..................................... P609221
filter, safety........................................ P608599
Vacuator Valve.............................. P158914
B055006
B080074
cover.................................................. P609219
filter, primary..................................... P609218
filter, safety........................................ P602427
Vacuator Valve.............................. P158914
cover.................................................. P605731
filter, primary (metal liner).............. P611190
filter, safety........................................ P611189
Vacuator Valve.............................. P158914
43
MEDIUM DUST
Outlet to
Engine
FKB Service Instructions

Recommended Maintenance Procedures
1
2
MEDIUM DUST
Shut off your engine
Remove service cover
Remove the filter
Gently pull the filter out of housing. Avoid

dislodging contaminant from the filter or
knocking it against the housing.
Clean the inside surface
With a soft rag, thoroughly clean the inside surface of the housing.
Be careful not to introduce contaminant into the outlet tube.
Check the safety filter
Check safety filter for damage. If damaged,

replace. Also check to insure that the
safety filter is properly seated in the
housing. It should fit snugly inside the
outlet tube.
Install the new filter
Install new filter. On FKB04, 05 and 06 models, press and rotate

filter clockwise until fully engaged to stop. For the FKB08 radial
seal filter, push straight in until seated firmly.
Unlatch and remove the service cover.

To remove the primary filter on FKB04,
05 and 06 models, press and rotate filter
counterclockwise until filter is free. The
FKB08 primary filter is a radial seal design,
gently move the end of the filter back and forth to break the seal.
7
8

Replace the cover
Replace the service cover. The INLET

arrow should line up with the air cleaner
inlet. DO NOT force cover onto air
cleaner. The cover should go on with no
extra force. If cover is not flush to the
body, the filter is not properly seated in
the housing.
Refasten the latches
Refasten latches to secure cover.

Make sure that latches penetrate the
slots in both the body and the cover.
10

Inspect
Inspect and torque all clamps, bolts

and connections in the entire air intake
system. Check for holes in piping, and
repair if needed. If Vacuator Valve is
damaged replace.
11

Restart the engine
Inspect the new primary filter
Inspect the new primary filter carefully. Check for any voids, cuts,
tears or indentations in the urethane-sealing surfaces.
Installation Recommendations
Shut off your engine.
Air cleaner orientation is horizontal, with the drop tube pointing down - within +/- 15. For service
clearance, allow the entire length of the filter for removal and 35mm for service cover latches.
Mounting is M8 x 1.25, with a maximum torque of 15 ft. lbs.
Connections: Inlet/Outlet maximum torque 40 in. lbs. Indicator port maximum torque 1.5 ft. lbs.
Inlet accessory note: The air cleaner housing can accommodate a lightweight inlet hood, but not a
pre-cleaner or any other accessory. Use of an unapproved intake accessory will void your Donaldson
warranty.
44

Gradall Crawler Vendor Service Manual

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XL SERIES CRAWLER

Form No. 29635

NOTE! High Pressure denotes 10,000 psi gauge

Form No. 29635 3/47

Form No. 29635

WARNING: This symbol indicates a hazard which could result in death or

CAUTION: This symbol indicates a hazard which could result in injury or

Form No. 29635 3/97

Form No. 29635 3/97

Keep the machine lubricated per lube chart.

Keep a supply of metric fasteners in stock to replace broken or lost components.

Form No. 29635 3/97

II. Track Adjustment

TO ADD GREASE TO THE TENSIONING CYLINDER, PROCEED AS FOLLOWS:

Form No. 29635 3/97

II. Track Adjustment (continued)

Form No. 29635 3/97

II. Track Adjustment (continued)

III. Shoe Contact with Rock Guard

Form No. 29635 3/97

IV. Crawler Travel Speed

Repeat step 6 for reverse travel.

Form No. 29635 3/97

IV. Crawler Travel Speed (continued)

To Check Undercarriage Tracking Proceed as Follows:

Form No. 29635 3/97

VI. Track Chain

Reverse the procedure for reassembly.

Form No. 29635 3/97

VI. Track Chain (continued)

Form No. 29635 3/97

VI. Track Chain (continued)

Form No. 29635 3/97

VI. Track Chain (continued)

Form No. 29635 3/97

VI. Track Chain (continued)

Form No. 29635 3/97

VI. Track Chain (continued)

Master Pin and Bushing

Form No. 29635 3/97

VI. Track Chain (continued)

Form No. 29635 3/97

VII. Track Rollers

Form No. 29635 3/97

VII. Track Rollers (continued)

Fill roller with lube. See Table 5.

Install O-ring on the roller shaft.

Form No. 29635

VII. Track Rollers (continued)

Remove lube fill plug and dump lube into a container.

Track Roller Assembly (See Figure 21)

Install bushings into roller shell.

Form No. 29635 3/97E

VII. Track Rollers (continued)

Form No. 29635 3/97

VIII. Idler Roller with Track Tension and Adjuster Compartments

VIII. Idler Roller with Track Tension and Adjuster Components

Form No. 29635 3/97

If necessary, remove the remaining dowel pins and bracket.

Press the bushings into the idler shell.

Form No. 29635 3/97

Form No. 29635 3/97

Form No. 29635 3/97