CONDOR Scissor Lift 3172 Parts Manual Sn 2698 - PDF DOWNLOAD

PARTS MANUAL SELF-PROPELLED AERIAL WORK PLATFORM

3172 SCISS

CALAVAR CORPORATZOB provides this manual for the guidance of all owners, operators and servicing personnel in order to obtain the longest possible trouble-free service. It contains general data, oper... ating instructions, lubrication procedures, mantenance procedures, illustra1!ed parts breakdown, vendor's information and safety rules. Additional copies of this parts book (P/N 92275) may be obtained through the Parts Department at CALAVAR.

Delivered ___________________ SHOWN MODEL 31726

customer __________--------________

CORPORATION

MANUAL 92275 8300 IMPERIAL DRIVE. WACO. TEXAS 76712

(817)666-4545

FAX (817)666-4544

FROM SERIAL NO. 2698

ISSUED DBCBKBBR 1991

TABLE OF CONTENTS GENERAL SECTIOB

Specifications •••••••••••••••••••••••••••••••••••••••••• 1 Introduction 1. Description of Scissor ••••••••••••••••••••••••••• 2 2. operator's Qualifications •••••••••••••••••••••••• 2 3. Danger, Caution and Warning Decals ••••••••••••••• 3 Warranty •••••••••' ••••••••••••••••••••••••••••••••••••••• 5 Warranty. Claim •••••••••••••••••..••••••••••••••••••••••• 6 How to F1ll out - Procedure ••••••••••••••••••••••••••••• 7 Loading Transporting and Unloading 1. Loading and Unloading •••••••••••••••••••••••••••• 8 2 • Ramp Method •••••••••••••••••••••••••••••••••••••• 8 3. Forklift Loading/Unloadinq Method •••••••••••••••• 8 4.

Transporting ••••••••••••••••••••••••••••••••••••• 9 Conversion Table Degrees to Percentage •••••••••••••••••• 9 Pre-Operation Inspection 1. Overall Machine Condition ••••••••••••••••••••••• 10 2. Platform ••••••••••••••••••••••••••••••.••••••••• 10 3. Batteries/Charger ••••••••••••••••••••••••••••••• 11 4. Hydraulic System ••••••••••.••••••••••••••••••••• 11 5 • Engi~e •• ~ ••• 6 •••••••••.••••.•..•••••••••••••.••• 11.

6. Mult~-Ax~s 5 Slope Sensor •.••••••••.••••••••••• ll Control Familiarization and Limitations 1. Platform Capacity .•••••..••••••••••••.•••••••••• 12 2.

3•

Travel ••••••••••••••••.••••••••••••••••••••••••• 12

Ground Controls ••..••.••..•••.•••••••••.•.•••••• 13

Platform Controls ••.••••••••••••••••.••••.••••.• 14 Operational Procedure 1. Operation from Ground Controls ••••••.••••••••••• 15 2. Operation from Platform Controls •••••••••••••••• 16 4.

3• 4.

L~mi t Switch •••••••••••••••••••••••••.•••••••••• 17 Shut Down ••••••••••••••••••••••••••••••••••••••• 17

5 • Emergency Lowering •••••••••••••••.•••••••••••••• 17 Brake Re eased/Free Wheeling ••••••••.••••••••••• 17 Preventative Maintenance 1. Service Tools •••..••.•••.••.•••.••••..••••••.•.. 18 2. Hydraulic System Care and Maintenance •••••.••••• 18 6.

3•

4.

5.

Batteries •••••••••••••••••••••••••••••••.•••.••. 19 Batte-ry Charging •••••.••••..••••••••••••••.•.••• 20

Engine •••••••••••••••••••••••••••••••••••••••••• 20

How to Order Parts •••.•••••••••••••••••••••.••••••••••• 21 Warranty Return Authorization Form ••••••••••••••••••••• 23 Do Not Rules ••••••••••••••••••••••••••••••••••••••••••• 24

VENDOR SECTIOH

Kohler M 18S Gasoline Enqine Eskridge 95W Multiple Disc Brake Parker Hydraulic PUmp TRW MAE Wheel Motor TRW ME Brake Wheel Motor PARTS SECT:tOH Illustrated Parts Breakdown SAFETY SECT:tOH

)

f) CALAVAR CORPORATION

BOLT TORQUE CHART SIZE

()

NOTES: 1. THIS CHART SHOWS STANDARD SOL T TORO TO BE A.PPllED UNLESS OTHERWISE SPECIF

2. CLAMP 3.

~OAD

= 75% X PROOF X

TOROUE (PL J = R D T R = . ZOO FOR DRY CONDITIONS

R = . 150 FOR LUB CONDITIONS ·LUB CONDITlONS· iNCLUDES LUBRIC PLA TING AND HARDENED WASHERS. D = NOMINAL JIAMETER IN INCHES "" T

=

DESIRED CLAMP LOAD IN POUNDS'"

/

APPENDIX B

II ) CALAVAR CORPORATION

BOLT TORQUE CHART METRIC HEX HEAD CAP SCREWS (REGULAR PITCH) • Suggested assembly torques in Foot-Pounds (. Values in Inch-Pounds) • The torque values for each diameter are acceptable for any thread pitch in that diameter

Propeny Class B.S

Propeny Class 9.S

Propeny Class 10.9

Propeny Class 12.9

Dry Threllda

Dry Threllda

DIAMETER

Dry Threllda

M4

27.5·

17*

30*

18-

38.5·

24*

53*

32.5*

M5

56.5·

33.5-

61-

37*

7S*

47*

107·

65*

M6

95*

57.5-

103*

61*

132*

79-

180*

109*

MS

19

12

21

13

27

16

37

22

M10

39

23

42

25

53

32

73

44

M12

67

40

73

44

92

55

127

76

M14

107

64

116

69

146

89

203

122

M16

167

100

181

108

230

138

316

190

M20

325

195

352

211

449

269

617

370

M24

562

337

609

386

775

465

1066

640

M30

1117

670

1210

726

1540

924

2188

1271

Lubricated Thnlllda

Dry Threllda

Lubricated Thrudll

Lubricated Thrudll

Lubricated

nv.cia

)

)

SPECIFICATIONS

')

SPECIFICATIONS

MODEL 3172 ELECTRIC

MODEL 3172 GAS

Maximum Working Height Extended Platform Height Stowed Platform Height Overa 11 Length Overa 11 Wi dth Removable Safety Rails Inside Platform Size Platform Capacity Gross Weight Power System Stabilizers Battery Capacity Number of Batteries Battery Voltage Battery Charger Toe Pl ate Wheel Base Wheel Track Tires Inside Turning Radius

31 ft.

25 ft.

4 ft. 3.5 in.

12 ft.

6' ft.

3 ft. 6 in.

140 x 68.5 in.

1,500 lbs.

5,520 lbs.

24 volt Optional 375 amp 8 6 volt 40 amp 6 in.

7 ft. 6 in.

5 ft. 1 in.

26 x 12.00 x 12 9 ft. 3.5 in.

31 ft.

25 ft.

4 ft. 3.5 in.

12 ft.

6 ft.

3 ft. 6 in.

140 x 68.5 in.

1,500 lbs.

5,120 lbs.

18 hp Optional 95 amp 1 12 volt

OPERATIONAL FUNCTION TIMES Lift Up Lower Down

()

(+

N/A

6 in.

7 ft. 6 in.

5 ft. 1 in.

26 x 12.00 x 12 g ft. 3.5 in.

10%) 19 sec.

22 sec.

19 sec.

22 sec.

3.2 mph 2.5 mph 0.75 mph 8 ft.

11 ft. 6 in.

2.5 mph 1 mph 0.75 mph a ft.

11 ft. 6 in.

DRIVE SYSTEM TIMES High Speed Low Speed Creep Speed High Speed Cut Out Creep Speed Cut Out

The CONDOR Model 3172 is designed and built to confonn to CALAVAR'S understanding and interpretation of all applicable OSHA rules and regulations as well as ANSI standards: • OSHA Title 29, Paragraph 1910.67 - -

Vehicle Mounted Elevating and Rotating Work Platforms - Labor

• OSHA Title 29, Paragraph 1926.556 -

Aerial Lifts - Construction

• ANSI Standard A92.6-1979 - - - - - -

Self-Propelled Elevating Work Platfonns

CAUTION

~

It is imperative that all owners and operators of the CONDOR read, understand and conform to these regulations. Ultimate compliance to prevailing OSHA regulations is the RESPONSIBILITY of the employer utilizing the equipment.

1

INTRODUCTION The primary purpose of this manual is to assist the operator and maintenance .~ personnel to better understandL operate, and maintain the self-propelled CONDOR SCISSOR aerial work pla~form in a safe and proficient manner.

This manual has been produced as a valuable tool for our customers. it consists of a General section, Vendor section~ Illustrated Parts Sect~on, and Safety section. It is in the best interest o~ eve~one involved with the operati~~ maintenance, and repair of the machine to READ and thoroughly UNDBRSTAMU all sections of this manual.

In general, this manual covers the servicing of the machine and associated standard e~ipment. In some cases CONDORS are supplied with various options and speciaIized equipment. If service information is not found in this manual and information is reqqired it is suggested that CALAVAR customer Service Department be contacted. The proper ~nformation will then be forwarded if available at time of request.

All product descriptions, illustrations and specifications were in effect at the time the manual was released for printing. CALAVAR CORPORATION reserves the right to make changes in desiqn or to make additions to or improvements in its products with9ut imposing any obligations upon itself to instal1 them on its products prev~ously manUfactured.

1. DBSCRIPTION OPSCISSOR The CONDOR SCISSOR is a vertical Scissor arm aerial work platform and is rugged, maneuverable and safe. It is designed for work on firm level surfaces with normal operation controlled by an operator using a control box in the platform. All operational modes can be accomplished from the platform ~ncluding drive and steer.

The CONDOR provides industrial, construction and ma,tntenance workers the ability to safely elevate and perform insta1lation, ma~ntenance, and replacement tasks •.

The Model 3172 is powered by a Kohler Model M18 air-cooled gasoline e n g i n e - \ rated, at 18 horsepower, at 3,000 RPM. Electrical unit is powered by six volt ) D.C.~ eight batter~es producing a 24 volt D.C. system.

Each batte~ is rated at 3/5 ampere hours. A 24 volt, 40 amp batte~ charger with 110V input is used to recharge the batteries after each day's u~e. Hydraulic system is 8.5 GPM @ 3,000 RPM at operating pressure of 2,400 ps~.

2. OPERATORS QUALIPICATIONS Each CONDOR SCISSOR has undergone a thorough Quality Control inspection at CALAVAR. The desiqn incorporates built-in saiety features. A person of average skill can readily become proficient and safe in the operation of the CONDOR. It is a personnel. lifting device and can be potentially DANGBROUS in the hands of UNTRAINED or CARELESS OPBRATORS. Knowing the characteristics of the machine and function of the controls is important to SAFB, PROPBR OPBRATION AND USB. Become familiar with the controls and prac~ices will result in smootht accurate positioning.

It is the responsibility of all users to READ and COHP Y with the following RULBS and information desiqned to promote SAFETY and UNDBRSTANDING of the CONDOR. A thorough understanding of the operating characteristics and limitations of the CONDOR is always the first re~irement for any use~, regardless of his prior experience with similar types of

•

equ~pment.

•

Only OUALIPIED/TRAIHBD and AUTHORIZBD personnel must be allowed to operate the CONDOR. A QUALIPIBD/TRAIHED operator is one who has READ ana UNDBRSTOOD the instructions in this manual and is thoroughly fa~iliar with the operating characteristics and limitations of the un~t. .

•

ENOW and POLLOW all cautions, warnings and operating instructions on the CONDOR.

2

)

•

Repairs and adjustments should be made only by QUALIFIEDITRAINED personnel.

•

No MODIFICATION is to be made to the unit without prior written consent of the CALAVAR Engineering Department.

•

UNDERSTAND and OBEY all Federal, State and Local statutes and regulations applying to safe operation and use of aerial work platform.

YOUR SAFETY I S OUR UTMOST CONCERN AND YOUR RESPONSIBILITY

3. DANGER, CAUTION and WARNING DECALS are designed for your protection. and adhere to the information they provide.

STOP

)

CAUTION GUARD RAILS AND SAFETY CHAINS MUST BE SECURED AND USED AT ALL TIMES

READ OPERATING INSTRUCTIONS BEFORE OPERATING MACHINE

- WARNINGDO NOT WORK UNDERNEATH THIS LIFT UNLESS ARM STAND IS LOCKED IN PLACE See Service Manual for location

UNLAWFUL TO OPERATE THIS EQUIPMENT CAUTION CAUTION CAUTION CAUTION WITHIN 10 FEET OF HIGH VOLTAGE LINES

LOAD CAPACITY (EVENLY DISTRIBUTED LOAD)

MODEL 3172 ------- 1,500 LBS.

3

Know

CHECK BATTERY WATER LEVEL ONCE A WEEK.

BATTERY CHARGER PLUG 115 VOLT ONLY

This machine has been designed and tested to meet these standards:

FREE WHEELING· VALVE )

ANSI A92.2 1969 ANSI A92.3 1973 OSHA GISO 1910.67

1. STARTING:

OPERATION SHEET WARNING: Machine is to be used on leuel ground only.

WARNING: Don't eHceed load limit on specfic models.

3. LIFT: Io~ring the platform from the lower centrol panel, make sure that the selector switch, in the lower centtel panel. is in tha down position. Push tha toggla switch for lift to either the up or down position.

B. Raising and lowering the platform ftem the tapper centrol box, fitst make sure that the selec&:or switch In the lower centref pane. is in the up position Push in the dead man switch on the left side of the upper centrol box. M. the same time push the lift s.witch to tha up position.

C. 80th rift switches are of the momentary type; when the switch is released it will automatically return to tha off position.

A. Tum Master Disconnect Switch On 8. PuJI out the power switch on the lower centrol panel.

C. Push selector switch to UP on the lower centro. panel.

D. PuR out the emergency ONIOFFbutton in the . center of the upper control box.

A. When raising and

2. STEERING:

A. The steering is done by pushing in on the

dead man switch on the left side of the upper centrol box and. by pushing the toggle switch for steering.

8. Pushing the steering switch to the left. the front wheels will go left and remain to the lett until the toggle switch is pushed to the right.

C. The steering switch is a momentary type switch. When the operator feleases the switch it will automatically retum to the off position.

)

4. DRIUE:

A. Forward and reverse travel is dona from the upper centroC box only.

B. The machine has two speeds. high and low. Seled either high or low speed with toggle switch rnali<ed high or low speed.

C. Push the dead man switch In and then push the toggle switch mariced drive forward or reverse.

S. FREE WHEELING:

A. For loading. Unloading and free wheeling at low speed without damage to any of the ccmponents or

structure.

B. Fr. . wheeling vaNe Is on cross member at ..ear of

machine.

4

')

WARRANlY

Self - Propelled Booms and Scissors

WARRANTY Calavar Corporation ("Calavar") warrants to the purchaser that each new aerial work platform made by Calavar is free from defects in material and workmanship arising under normal use and service, in the case of major weldments (chaSSiS, turret and booms), for a period of 5 years after the original shipment of the aerial work platform from Calavar's plant; and in the case of all other parts, for a period of 1 year after the aerial work platform is first placed in service or two years after the original shipment of the aerial work platform from Calavar's plant, whichever occurs first.

The obligation and liability under this Warranty is expressly limited to repairing or, at Calavar's option, replacing free of charge, at its factory in Waco, Texas or at an authorized repair facility designated by Calavar, the defective part. In no event shall Calavar or its suppliers be liable to the purchaser or any other person for transportation charges or for any incidental, collateral, special or consequential damages, including without limitation damages for loss of profits, loss of customers, loss ofgoodwiU orworkstoppage, claims by any party other than the purchaser, or any other similar damages or loss even if Calavar, its suppliers or its representatives have been advised of the possibility of such damages.

Parts claimed to be defective and for which repair or replacement is desired shall be returned transportation prepaid to Calavar's factory for inspection. This Warranty applies to replacement parts provided under the terms of this Warranty only for the remainder of the Warranty period applicable to the original purchase. , Any operation of the equipment beyond rated capacity, improper use or application of the equipment, substitution upon it of parts not approved by Calavar or alteration or repair of the equipment by any person not authorized by Calavar shall, at Calavar's option, void this Warranty. Calavar shall have no liability or responsibility for damages resulting from accident or the malfunction of equipment and components not supplied by Calavar.

No agent, employee, distributor, dealer or other representative of Calavar is authorized to mOdify this Warranty in any way. Accordingly, additional statements or presentations by any such representative, whether oral or written, do not constitute warranties by Calavar and should not be relied upon as limited warranties of Calavar, and no attempt, effort or promise to repair equipment by Calavar or any such representative at any time shall modify or extend this Warranty in any way. If the purchaser has used its own order form, no additional or different warranty terms contained in purchaser's form will be honored by . Calavar. This Warranty covers only new and unused aerial work platforms manufactured by Calavar.

Products or parts manufactured by others are covered only by such warranties as are extended to the purchaser by Calavar's suppliers.

This Warranty is in lieu of all other warranties, expressed or implied, including but not limited to warranties of merchantability and fitness for a particular purpose. Any applicable implied warranty shall be limited in duration to the warranty period.

)

8300 Imperial Drive, P.O. Box 21447, Waco, Texas 76702·1447·817·666·4545, 800·877·5544, 817·666·4544 FAX Form No. 513·3M·392

EHective Date 911/90

5

WARRANTI ClAIM FORM

WARRANTY CLAIM MAIL TO CALA VAR CORPORATION

m

P.o. BOX 21447. WACO. TEXAS 76702-1447 817-666-4545 FAX 817-666-4996 800-8n-5544

NAME

[!]

OWNER

(}]

DEALER

ADDRESS STATE

CITY

ZIP

NAME SUBMITTED BY ADDRESS CITY

0

STATE

[!]

ZIP

DEALER CLAIM NO. UNIT SERIAL NO.

MODEL

CALAVAR WARRANTY NO.

DELIVERY DATE

RETURN AUTHORIZATION NO.

IN SERVICE DATE

DATE PARTS RET.

DATE OF CLAIM

DATE OF FAILURE

DATE OF PARTS REP1...

CONDOR

0

OTY.

FIREBIRD

0

SCISSORS 0

REPLACEMENT PART 0

0

PART NUMSER

INVOICE NUMBER

DESCRIPTION

LIST EACH

NeT AMOUNT

/j

[2]

LASOR HOURS

LASOR DESCRIPTION

AMOUNT CLAIMED

LASOR

TOTAL LAIIOR

I

APPROVED BY:

TOTAL PARTS

TOTAL LASOR 6 PARTS

DATE:

I[ 8] CALAVAR THIS SPACE TO BE USEO FOR APPROVALDNLY

APPROVED AMOUNT

REMARKS: PARTS LABOR TOTAL

) APPROVED

0

WHITE- CALAVAR

DENIED

0

GREEN -CALAVAR

DATE:

SIGNED YELLOW- DEAlER FILE COpy

PlNK-CALAVAR

6

GOLDENROO-CALAVAR

WARRANTY CLAIM PROCEDURE WARRANTY CLAIM This procedure is offered to assist you in properly filling out the Warranty Claim Form. The more information supplied on this form, the better CALAVAR can evaluate the problem and expedite processing.

The form should be typed or filled out legibly in ink. Several copies are utilized, thus ensure sufficient pressure-is applied to make all copies legible.

HOW TO FI LL OUT - PROCEDURE

1.

Where to mail claim - CALAVAR'S address, phone number.

2.

Dealer information: Name of company, address. name of person submitting claim. This will be the name used on all correspondence.

3.

Owner information: "SAME" .

4.

Claim information:

Name of company, address.

If same as No.2, write

A. Dealer's claim number: This is necessary as there may be more than one claim for this unit.

~,)

B.

CALAVAR warranty number: This will be completed by the Warranty personnel at CALAVAR CORPORATION. .

C.

Return Authorization number: If CALAVAR deems that the defectjve material be returned, a return authorization number will be assigned and appropriate paperwork will be mailed to the dealer/owner. Upon receipt of the paperwork, the dealer is to ship the parts freight prepaid to CALAVAR for evaluation and further disposition. All dates pertinent to the claim are to be registered. .,

)

5.

This area is provided to identify the unit: It is important to furnish serial number, date of delivery (date received by you), inservice date (date unit is sold by you or put into operation),model number.

6.

This area is for part number(s) and description(s}. The CALAVAR invoice number and amounts are necessary in order to properly process the claim. All dollar amounts are to be in U.S. currency.

7.

A detailed labor description is required in order to fully evaluate the hours of your claim and the amount CALAVAR will approve.

8.

This area is filled in by CALAVAR personnel and is for approval or denial of the claim and a brief explanation of steps taken.

9.

Upon completion of form, remove light yellow copy titled "Dealer Copy," retain, and send remaining copies to CALAVAR. 7

LOADING .. TRANSPORTING .. UNLOADING 1.

LOADING AND UNLOADING The CONDOR SCISSOR, although somewhat small in stature compared to larger type construction equipment, still requires the same care and attention in LOADING, TRANSPORTING, and UNLOADING, as does the larger, heavier type equipment. At no time should sight of this be OVERLOOKED. Before loading/ unloading the CONDOR, inspect for any physical damage or defects. DO NOT OPERATE A DEFECTIVE OR MALFUNCTIONING UNIT. The CONDOR SCISSOR Model 3172 electrical unit weighs approximately 5,520 lbs., and gas unit is approximately 5,120 lbs. Whatever means is used to load/unload the unit, should be of sufficient strength to withstand the wei ght of the CONDOR. DO NOT attempt to OPERATE the unit UNTIL you have READ and thoroughly UNDERSTOOD all INFORMATION provided on the operation of the CONDOR. FAMILIARIZE yourself with the CONTROLS, their FUNCTION and OPERATION.

2.

RAMP METHOD A. Ensure that ramp being used is sufficiently strong to handle the wreight of the unit.

B.

Ramp should be set at an angle no steeper than 18° or 32%. rise in 10 feet.

39 inches

C. Before driving the unit on the ramp, test all the controls and the brake system. Then move the CONDOR slowly back and forth.

D. Move the unit on the truck or trailer, up or down the ramp approximately a foot at a time allowing the steering corrections to be made. Keep unit in alignment with the carrier and ramp during loading or unloading procedure.

3.

FORKlIFT LOADING/UNLOADING METHOD A. Ensure that forklift has sufficient capacity to handle the weight of the CONDOR. B. The forks should be long enough to completely go across the width of the frame and should be positioned as close to the inside of the tires as possible. When lifting unit, center the forklift between the CONDOR tires.

C.

Unit should be picked up from side of unit and should only be raised to a height to clear any obstructions.

D.

Keep forklift travel with CONDOR load to a minimum and set gently down to ground level.

8

)

4.

TRANSPORTING The CONDOR can be easily and safely transported from job site to job site ,if a few simple rules and procedures are followed:

A.

Block all wheels to prevent forward and reverse motion.

B.

Tie down the CONDOR with chains or cables, running them through the tie-down brackets only. DO NOT chain or strap OVER the platform or GUARD RAILS. Severe damage to the scissor arms may result from excess pressure due to securing the unit over the top of the platform.

CONVERSION TABLE (DEGREE TO PERCENTAGE) 1007-

()

Since the conversion of gradeabiLity is often referred to in percentages and then on the other hand often reFerred to in degrees. this chort is being provided for your convien,ence to quickly convert percents to degrees.

957907-

851.

807-

757707-

651.

607-

551.

501.

457-

8300 {HPERIAL DRIVE, WACO, TEXAS 76712 (817)666-4545 FAX (817)666-4544

407-

351.

307-

25:' 207;51-

107-

51. ,...

)

----- 100 r : .

9

PRE - OPERATION INSPECTION The CONDITION of the unit prior to start-up is a very IMPORTANT FACTOR as it di rectly affects the operator s SAFETY. It should be a common practice that the operator perform a general inspection before each day's operation of the work platfonn. l

The purpose of the operator's inspection is to keep the CONDOR in PROPER working condition and to DETECT any sign of malfunction during normal operations between scheduled maintenance checks.

DOWNTIME is COSTLY and can be prevented by taking a few minutes prior to

start-up. A thorough walk-around inspection must be performed each day before the CONDOR is operated. Report damage of faulty operation immediately. Attach a sign at the ground control area stating aDO NaT OPERATE.· Repair any discrepancies before use. Some of the major items to check are:

1. OVERAll CONDOR CONDITION A.

Ground/platform controls ... all controls are to function properly.

B.

Hydraulic leaks.

C.

Electrical system for frayed or broken wires or loose connections.

D. Missing, broken, or damaged parts, pin retainers, bolts and nuts.

E. External structural damage, or cracked welds.

F.

Condition of tires ... pits, tears, cracks, or cuts.

G.

Steering connections, tie rod, cylinder.

H.

Wheel lug nuts ... missing or loose.

I.

Decals, placards, and warning signs.

J.

Proper tire pressure.

K.

Scissor arms ... pivots, connections, and lift cylinders.

)

2. PLATFORM A.

Pivot pOints, connections.

B. Structural condition ... damaged railings, flooring.

C.

Control box ... electrical wiring for frayed or broken wires, damaged components, hoses, loose connections.

D. Access opening, chain, fasteners.

(

10

)

3.

/)

4.

5.

)

6.

BATTERIES/CHARGER A.

Electrolyte level - all caps present.

B.

Cables and connections - ground connection.

C.

Battery hold down.

D.

Charger condition, meter, electrical plug.

HYDRAULIC SYSTEM

A.

Hydraulic leaks.

B.

Loose or damaged hoses, tubing.

C.

Fluid level hydraulic tank breather cap. Refill only with shell Tellus T-32'or Mobil DTE - 13M. DO NOT MIX different brands of hydraulic oil.

D.

Hydraulic valves and control levers.

E.

Cleanliness of hydraulic fluid - non-milky, bright in color ..

ENGINE (ENGINE POWERED UNIT) A.

Mounts and mounting bolts.

B.

Fuel tank level and connections

C.

Fuel leaks

o.

Condition of belts

E.

Oil condition, level and leaks

MULTI-AXIS SOSLOPE SENSOR (OPTIONAL) A.

General condition

B.

Loose or damaged wires

C.

Push to test.

O.

Warning buzzer in platform is operable

Moveable on mounting

KNOW THE UNIT AND ITS CAPABILITIES. Report any unusual operation. sway or motion of arms or platform while being operated. Excessive, noise. abnormally slow or fast operation.

I )

CAUTION

Erratic unusual

I

Defective components. structural damage, miSSing parts or equipment malfunctions jeopardize the SAFETY of the operator and other personnel and can cause extensive damage to the CONDOR. A POORLY MAINTAINED machine could become the greatest OPERATIONAL HAZARD you may encounter.

11

CONTROL FAMIUARIZATON AND LIMITATIONS It is important from a SAFE operational standpoint that you, the operator, know the function of each control, its 1imitations, as well as that of the unit. A good understanding of the controls, limitations and capabilities will enhance operation and assure maximum operating efficiency and safety.

1.

PLATFORM CAPACITY The platform capacity of the CONDOR SCISSOR is unrestricted and is applicable within the operational envelop/positions when operated on a firm level surface and slope not exceeding 5°. The capacity includes the required OSHA and ANSI safety margin. DO NOT lessen the SAFETY MARGIN by overloading ~he platform beyond RATED CAPACITY.

PLATFORM CAPACITY - - - - - - 1,500 lbs.

The platform capacity noted above is the COMBINED WEIGHT of all personnel, their tools, and any other equipment or materials carried by the platform.

Larger platforms require de-rating capacity.

I

WARNING'

Proper stability of the CONDOR is based and tested on the standard unit and all of its components as supplied by CALAVAR. Any modifications of the unit, either by the addition or removal of parts and/or weight can greatly affect the unit's STABILITY and SAFETY.

)

2. TRAVEL Travel can be accomplished from both the stowed position or with platfonm elevated. Although the gradability of the unit is 18° or 32%, this should only be negotiated with the platform in stowed position. The CONDOR is designed to travel with platform elevated on FIRM LEVEL surfaces and slopes not exceeding 5°. The parking brake is spring applied and hydraulically released. This brake releases when the drive circuit is energized.

Maximum travel speed is 2.5 MPH for gas unit and 3.2 MPH for electrical ~nit.

This is high speed travel and is available when platform is in the stowerl position (fully lowered). Low speed mode is available by moving high/lo~ SPEED toggle switch to "LOW." Creep speed mode is automatically shifted when scissor is elevated 1116" high.

Steering is accomplished through a tie rod and hydraulic cylinder arrangement. Although the STEERING toggle switch is momentary, return to center pOSition, the steering system itself is not self-centering. Therefore, the toggle switch direction must be reversed when turn is completed in order to return to straight line travel. DEPRESS and HOLD appropriate side of switch for desired steering direction. II FORWARD " motion is determined with STEERING wheels leading the way. DRIVE toggle switch AWAY from the operator for FORWARD motion; TOWARD the operator for REVERSE motion.

12

)

Prior to making any attempt to operate the CONDOR SCISSOR, it is essential that the operator be thoroughly familiar with the location and function of each control. The following will assist in accomplishing this required understanding.

3. GROUND CONTROLS The ground controls are primarily emergency type controls. The panel is located on the left-hand compartment facing forward. Driving and steering is not possible from this location.

• KEY SWITCH The ground control has a MASTER DISCONNECT SWITCH. The key straight up center position is ·OFF n and disconnects power. With switch in nON" position, the electrical circuit is energized. Gasoline engine unit, actuate switch ·START n to start engine. Switch must be -ON D to energize ground or platform controls.

• CHOKE SWITCH

c)

Pump switch to activate engine choke. May be used in conjunction with engine START key switch. Purpose to assist starting of engine first time 'in morning or after long periods of non-use. Actuate CHOKE switch ·PUSH INB for operation.

• POWER BunON The control panel has a 2 position POWER switch: ·PUSH OFF· position disconnects all power from the batteries; the "PULL ON D position energizes the power circuit.

• SELECT SWITCH Two-positioned toggle switch for selection of operation from ground control or platform controls. The "DOWN· position directs the power to the ground control panel. The ·UP· position directs the power to the aerial platform controls.

• LI FT SWITCH Momentarily, return to center, toggle switch to raise or lower scissors.

Actuate switch to -UP· position RAISES scissors; uDOWN u position LOWERS sci ssors.

• CIRCUIT BREAKER

!)

A 20 amp circuit breaker is used to protect the electrical system. Should it pop out, it is due to overload or short-circuit; and cause should be investigated before further operation.

13

4.

PLATFORM CONTROLS The platform controls are located on a movable console and can be slid over the top railing of the platform which gives the best control advan~age for the operator. The platform control box contains controls for compl~te operation of the units. The controls are energized only when the FOOT SWITCH is depressed and held. The platform control box contains the following controls:

•

EMERGENCY ON/OFF BUTTON UPULL U to turn ON and uPUSH- to turn OFF. NOTE - This is also an emergency switch. PUSH TO STOP ALL FUNCTIONS.

•

DRIVE FORWARD/REVERSE UFORWARD U motion is determined with STEERING wheels leading the way. uREVERSE u motion is determined with DRIVE wheels leading the way.

•

HIGH/LOW SPEED Toggle switch for selection of travel speed. Actuate switch uAWAY u fre>m operator for HIGH speed; uTOWARD u operator for LOW speed.

NOTE - High speed can only be obtained with stowed pOSition. CONDOR has three speeds; at 8 ft., the LOW speed, and at 11 ft. 6 in., the LOW speed will automatically be activated. This will occur even if HIGH/LOW switch is in HIGH position.

•

STEER - LEFT/RIGHT Toggle switch for control of steering wheels. Switch is momentary, meaning it returns to center position when released. Actuate switch to °LEFTu to turn wheels for LEFT turn; uRIGHT u for RIGHT turn.

•

LIFT - UP/DOWN Toggle switch for raising or lowering scissor. Move switch MAWAYo fran operator to UP scissor; "TOWARD Moperator to DOWN scissor.

STEER LEFT'

RIGHT

©>

LIFT

EMERGENCV

SPEED

DRIUE

UP

PULL ON

HIGH

FORWARD

(Q)

(Q)

(Q)

(Q)

PUSH OFF

lOW

REVERSE

DOWN

)

14

OPERATION PROCEDURE

/,

) Prior to operation of the CONDOR for your OWN SAFETY, it is your RESPONSIBILITY . to ensure that the unit is in proper ,working condition and that the PRE-OPERATION INSPECTION has been performed.

I

CAUTION'

Located on the inside cover of Safety Manual PIN: 92271 are a·few DO NOTS relative to proper operation and maintenance. ACQUAINT yourself with these simple RULES and be ALERT to their signs.

I

WARNING

I

OBSERVE All SAFETY PRECAUTIONS WHILE OPERATING THE CONDOR. Before starti ng t on battery power units, disconnect the external power source from the machine's battery charger. On engine powered units, check fuel level for any leaks in fuel system.

1. OPERATION FROM GROUND CONTROLS •

Pullout the POWER switch to -ON· position.

•

Gas unit, turn KEY switch -ON- to position. Engine power unit required ·START.- It may be necessary to choke engine. Actuate CHOKE switch, ·PUSH IN- for operation.

•

The propane-gas fuel SELECTOR switch is used. for engaging the propane or gas fuel solenoid. When the selector is in the ·GAS H position, the gas solenoid in the engine has been energized so as to allow fuel to flow through.

Conversely, when the selector switch is in the uPROPANE- pOSition, the propane solenoid has been energized. When the gas solenoid is energized, fuel will not flow through the propane solenoid, as it has not been energized; and when the propane solenoid has been energized, fuel will not flow through the gas solenoid.

• As the fuel in the propane tank is under pressure, the propane fuel will flow toward the solenoid at all times. (Fuel will not flow through the solenoid unless the solenoid is energized.) The primer button located in the upper control box and on the lower control panel energizes the propane solenoid only if the propane selector switch is on position and only as long as the button is depressed, to allow propane to flow to the carburetor, which facilitates easier starting.

•

Raise platform by actuating the LIFT toggle switch to ·UP- position.

WARNING - Check for overhead obstructions as well as at each end before raiSing platform. For lowering platform, actuate toggle switch to !lDOWN" pOSition.

At the end of the operation, push in POWER switch to ·OFF- pOSition at both control panels. If the machine will not be used for a period of time, reconnect power source to battery charger on electric units.

15

2.

•

OPERATION FROM Pu\TFORM CONTROLS Disconnect external power from battery charger on electric powered un; ts.

• At the ground contro 1s, pu 11 out POWER swi tch to ·ON" pos it ion, and tu rn KEY switch to RON· position.

•

Start engine on engine powered units •.' NOTE - Engine can be started from either the ground -panel. or platform.

• Move SELECTOR switch to DUp· position, then enter the platform of the CONDOR with the access provided. Close the platform entrance with the chains provided.

• On the control console, pull POWER switch to "ON· position. For units equipped with engines, START button must be activated to START engine.

•

Depress the FOOT SWITCH and HOLD. This will energize the control circuit as long as the foot switch is depressed.

•

DRIVE To operate DRIVE toggle switch in desired direction of travel, make SUIRE area around the machine is CLEAR before traveling. FORWAROoREVERSE direct; ons indicated on control panel refer to control with the platform control console mounted on the guard rail at the end of the platform farthest from the entry.

All directions are relative to FACING the control console while in the platform. CONDOR has three speeds: high, low and creep. Select either high or low speed. Maximum high travel speed is 3.2 MPH (Elec.) or 2.5 MPH (Gas). Maximum gradability 18° or 32%.

•

~.

)

STEERING Controlled by actuation of the toggle switch. Move switch in desired direction and hold until turn is complete. Switch will return to center position; however, steering wheels will remain in last activated pOSition. To center wheels, move switch in appropriate direction until travel is straight.

•

LI FT UP /DOWN PU\TFORM To LIFT platform, move the UP/OOWN switch to RUPU position, holding until desired height is obtained. To LOWER platform, move the UpoDOWN switch to ·DOWN D position.

I

WARNING'

You are head and shoulders above the platform railings. Be sure sufficient OVERHEAD clearance exists before raising. platform. When lowering platform, make sure area is clear of personnel and obstructions in path of plat€orm.

16

'\.. )'

3.

LIMIT SWITCH Raising the platform to 8 ft. will cut out the high speed drive and will automatically put the CONDOR into LOW speed drive. Raising the platform to 11 ft. 6 in. will cut out the low speed drive and automatically put the CONDOR into CREEP speed drive.

4.

SHUT DOWN Turn KEY switch at ground contro"ls to DOFFa pOSition., then DPUSH OFF D POWER switch. Electrical power unit must recharge batteries after each work shift.

When the CONDOR is not being used, batteries should be charged at least once a week.

5. EMERGENCY LOWERING For emergency use when no power exists, the platform can be lowered by a manual means. This can only be accomplished at ground level. The emergency lowering valve is located inside the compartment where ground control is located.

To operate, turn valve handle COUNTERCLOCKWISE. This will open the line allowing platform to descent under gravity.

To stop descent, turn valve handle CLOCKWISE. This will close the line stopping descent.

\)

Be sure valve is closed before performing normal' operation, otherwise platform cannot be raised.

6.

BRAKE RElEASED/FREE WHEELING The brakes are a multiple disc brake, liquid cooled (hydraulic oil). The brake(s) is released by hydraulic pressure (400 to 500 psi), applied to the piston to compress the springs. The brake is self-applying with zero pressure, producing maximum brake torque.

Since the incorporation of an open center spool, the need for a freewheeling valve has been eliminated.

To set the CONDOR in freewheel mode - Energize drive circuit, with SCISSOR in low speed, while Simultaneously closing the needle valve (black handle) on the pressure reducing valve. This lock opens the piston inside the brake.

To reinstate braking, open the freewheeling needle valve.

A CAREFUL, TRAINED, AND OBSERVANT OPERATOR IS THE GREATEST SAFETY DEVICE AVAILABLE

.)

17

PREVENTNE MAINTENANCE In conjunction with the PRE-OPERATION INSPECTION, a good preventative maintenance program will enhance a properly operating machine and the SAFETY of those operating and using the equipment. AN OUNCE OF PREVENTION lS A POUND OF CURE. This section-of the manual is directed to those items of maintenance of which the operator should be aware and which can be accomplished by or for him prior to operation of the equipment. Refer to SERVICE MANUAL for a more detailed breakdown and recommended time interval of PREVENTIVE MAINTENANCE.

I

CAUTION

I

DO NOT perform any maintenance or repair on the CONDOR, several basic tools are required. The following list of tools should be available.

1.

SERVICE TOOLS To properly and efficiently service you CONDOR, several basic tools are required. The following list of tools should be available.

2.

A.

Volt/OHM meter.

8.

Hydraulic pressure gauge (0-3,000 psi).

C.

#6 JIC swivel run tee and proper hose connection to gauge and run tee.

D.

Battery hydrometer.

E.

Battery load tester.

F.

Standard mechanics hand tools.

G.

Electrical test light.

)

HYDRAULIC SYSTEM The CONDOR SCISSORS hydraulics are used to power the various operational functions. As with any operational system, it is only as good as it is maintained. This section is offered to alert you and guide you in maintaining the hydraulic system. CAUTION - One of the major contributors leading to malfunctions in a hydraulic system in CONTAMINATION. Care must be exercised to prevent dirt from entering the system. ALWAYS CAP or PLUG OPEN PORTS AND HYDRAULIC LINES. A.

FLUID LEVEL - Check level daily. Maintain fluid level at full mark on side gauge with the unit in fully retracted position. (

18

)

/)

B.

OIL FILTER - Change return line filter located on hydraulic tank after the first 30 days or 50 hours of operation. Thereafter, change the filter every 3 months or 300 hours of operation.

C.

TANK BREATHER - Clean every SO hours of operation. and clean with solvent.' Air blow dry.

D.

HYDRAULIC TANK - Drain-oil from tank every 500 hours of operation or yearly, whichever comes first, and replace filter element. Add oil to tank to required level.

CAUTION

Remove from tank

I

Use only Shell TELLUS T-32 or Mobil DTE-13M. DO NOT MIX different brands of hydraulic oil or hydraulic oil with automatic transmission fluid. It may be necessary to lubricate or service the hydraulic system more frequently when operating CONDOR SCISSOR in severe environments, such as dusty condttions.

BATIERIES A.

Check electrolyte level (water) in batteries once a week and fill to proper level using distilled water. CAUTION - Add water only when batteries are fully charged to reduce the possibility of over filling.

B.

Check battery connections for corrosion and condition at least once a week.

C.

Periodically wash batteries off with clean water to reduce current leakage across a dirty battery surface.

D.

NEVER let the batteries stay completely DISCHARGED. Batteries should be charged at the end of each work day with the charger time set to accommodate overnight charging. A fully charged battery will have an electrolyte specific gravity of 1.265 to 1.285 at electrolyte temperature of 77.

I \)

CAUTION'

Low battery voltage (discharged) requires higher current draw to do the same work. This high current draw WILL DAMAGE the electric motor, relay contacts and the batteries. DO NOT OPERATE the unit with a battery DISCHARGED or that has a specific gravity of 1.130 or LESS.

19

()

IMPORTANT CHECK BATTERY .WATER LEVEL· AT LEAST

ONCE AWEEK.

4.

BATTERY CHARGING A. DO NOT charge batteries unless the electrolyte level has been B.

c~ecked.

Operate charger in accordance with the battery charging instruc~ions.~

C. Make sure the charger INPUT A.C. VOLTAGE is the same as the rating of the battery charger.

vol~age

D. Avoid arcing battery conditions. DO NOT smoke or INTRODUCE a FlAME or spark in the CHARGING AREA. E.

Use protective face and eye equipment when checking the condition of charging batteries.

I

DANGER

I

Lead acid batteries generate highly explosive hydrogen gas especially d~ring the charging cycle. To AVOID the possibility of an explosion, charge batteries ONLY in a well VENTILATED AREA. Keep fire, sparks and burning material away from the charging area. Do not smoke near a battery, and always shield the eyes when working near a battery.

5.

ENGINE Refer to engine manufacturers recommended maintenance and service procedure for lubricant and time interval.

20

lJ

HOW TO ORDER PARTS 1.

Always give serial number and model of COBDOR SCISSOR. each unit name plate shown right).

This manual is being released to cover COIIDOR SCISSOR units starting with serial numbers (SIN) 2698 to current production.

Some components used on earlier units differ from current productions. Where this occurs, the part is identified by a serial number.

NO'1'Z:

2.

(Refer to

~ 8300 Imperial Drive ~ Waco, Texas

7671l

CONDOR MOlijLSlRlAl. 110-_ __ ASSEMIU 110-_ _ _ _ _ _ _ __ PAAT NO-_ _ _ _ OArE OF MFG-, _ __

MAXIMUM PLATFORM KEIGKT - _ _ _ _ __ MAXIMUM HORIZONtAL REACK-, _ _ _ __ RATe~

WORK LOAD -

HYORAUllC OPERATING PRESSURE U$, PATElIl 4501.'"

THIS UNIT IS NOT ELECTRICAllY III$ULAnO THIS MOBILE UNIT CONFORMS TO ALL APPliCABLE AEOUIAEMEIITS OF AIISI &tU-lt••

PSI

Always specify part number and complete name of parts ordered.

A.

Check your required part and its attaching parts and match with the illustration page.

B.

Refer to corresponding item number in the parts listing page.

C.

Part numbers are located in the part number column.

D.

When ordering variable or optional miscellaneous parts which are not found in this parts section, follow the above outlined procedure of how to order parts.

()

(1) When applicable, give model and serial number of the component for which parts are desired.

(2) In a specific, difficult to describe situation, a photograph or detailed sketch would be helpful.

marked~up

3.

Do not designate quantity by "sets". parts are wanted.

4.

Always give complete address and full shipping instructions.

Specify parcel post, express, motor freight, air express, air freight, etc.

United Parcel Service, Emery, DHL, and Federal Express are available in designated areas.

5.

'1'0 ORDER

A.

state specifically how many

BY KAJ:L

Attention:

Parts Department

CALAVAR CORPORA'1'ION

8300 Imperial Drive Waco, Texas 76712

:)

lSS.

B.

BY FAX

(800) 443-5803 (817) 666-4996 (817) 666-4544

• Parts Department • General Office • Sales Department

21

c.

BY

PIlOn

...... ....

(817) 666-4545 (800) 877-5544

. .. .

6.

Parts and Service

RBTORB AOTBOlUZATIOII Parts returned without authorization will not be accepted.

If it is necessary to return parts for any reason, written authorization may be obtained from CALAVAR CORPORATIOII, Parts Department, Waco, TX 76712.

A Parts Return Authorization form is provided when CALAVAR deems it necessary to have the parts returned for evaluation. The form is issued by the Warranty or Parts Department of CALAVAR. A.

A Parts Return Authorization form (Refer to Next Page) will be filled out by CALAVAR unless requesting necessary information and you will receive a blue copy and white copy as well as a green shipping tag.

B.

Attach green shipping tag to part and insert return packing slip (blue copy).

C.

Ship part to CALAVAR PRBPAID.

D.

Parts must be returned to CALAVAR within 45 days from authorization.

@

date of

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22

WARRANTY RETURN AlITHORIZATION FORM

tj

WARRANTY RETURN AUTHORIZATION

COfIIIORATION

8300 IMPERIAL DRIVE, WACO, TEXAS 76712 (817)666-4545 FAX (817)666-4544

NO. SHOW.THIS NUMBER ON ALL CORRESPONDENCE. TAGS. DEBIT OR CREDIT MEMOS.

TO:

DATE: ATTN: REF. YOUR CLAIM II CALAVAR CLAIM II _ _ _ _ __

Sub Dealer'

The items listed below are authoriZed for retum 10 our faclOly. We are enclOsing shipping tagS for attachment to and/or enclosure with the Items being retumed. The BLUE copy of C&lavar's Retum Authorization must accompany the material you are returning. Retum only those items authorized. If a discrepancy in quantity or description developes at the time of shipment. please contact this office.

()

Tag No.

ALL ITEMS SUBJECT TO CALAVAR INSPECTION. ALL FREIGHT SHIPMENTS MUST BE "PREPAID" F.O.B. SANTA FE SPRINGS. CAUFORNIA. UNAUTHORIZED MATERIALS RECEIVED BY CALAVAR MAY BE REFUSED ANDiOR RETURNED FREIGHT COLLECT. THIS AUTHORIZATION EXPIRES AFTER FORTY·F1VE (45) DAYS FROM THE ABOVE DATE. INFORMATION REQUESTED ON THIS FORM MUST BE COMPLETED FOR EACH ITEM RETURNED. RETURNED MATERIAL DOES NOT GUARANTEE CLAIM APPROVAL.

Quan.

Calavar's Part Number

Part Description

Calavar Invoice Number

For additional items please attach a separaIe sheet.

If you need further aclvice or informatiOn regarding the items on this Retum Authorization. please contact our Warrenty Representative in Santa Fe Springs. CA.

SIGNED

REMARKS:

FOAM3IQAIMIIIIII

CALAVAR

DO NOT RULES Everyday application of product knowledge and common sense will help make CONDOR the safest tool you operate.

y~ur

1.

DO NOT operate the CONDOR unless you are qualified by training and experience in its safe operation.

2.

DO NOT overload the platform; know the rated capacity.

3.

DO NOT operate the CONDOR on soft or uneven surfaces. DO NOT elevate ~he CONDOR platform when machine is on a slope. (The CONDOR is designed t~ be used on firm and level surfaces only.)

4.

DO NOT elevate the CONDOR platform unless the guard rails access opening (entrance) is closed with the chains provided.

5.

DO NOT operate the CONDOR when the wind velocity exceeds 25 mph.

6.

DO NOT tow the CONDOR unless equipped with option for in-plant towing (5 mph max) .

7.

DO NOT jerk controls. movements.

8.

DO NOT force the platform or its railing against any adjacent structurE to brace the CONDOR unit.

9.

DO NOT sit or climb on platform railing. floor at all times.

Operate smoothly and deliberately into and out

~f

Keep both feet on the platform

10.

DO NOT allow overhanging loads on the work platform.

11.

DO NOT use ladders, planks, or other devices on the aerial platform for achieving additional height or reach.

12.

DO NOT operate a CONDOR that is malfunctioning.

13.

DO NOT perform maintenance with platform in an elevated position without the safety bar in place.

14.

DO NOT make any modifications to the CONDOR without prior written consent of the CALAVAR CORPORATION Engineering Department. DO NOT alter or disable any interlocks or other safety devices on the CONDOR.

15.

DO NOT operate near energized electrical conductors. This is a NONINSULATED aerial work platform. You must maintain a clearance of AT LEAST 10 FEET between any part of the machine or its load and any electrical power line.

16.

DO NOT use the CONDOR for any other purpose than to position personnel and their tools or equipment. The CONDOR is not designed for use as a crane.

17.

DO NOT recharge batteries near sparks or open flame. being charged ,emit highly expl osi ve hydrogen gas.

Batteries that are

WHEN PROPERLY MAINTAINED AND OPERATED CONDORS ARE SAFETY AERIAL WORK PLATFORMS! 24

)

J

11~r; f)

Torqmotor™ MG, MF, MB, ME Series Service Procedure

~.t) t\

TRW Ross Gear Division PRICE: $3.00 ,.

,

Torqmotor™ Design Features

COUPLING SHAFT HIGH PRESSURE SEAL .... u .....

THRUST BEARING

DIRT & WATER SEAL MATCHED ROTOR SET MATCHED COMMUTATOR SET

TorqmotofM MG Series features include: - 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 - MG 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 ratings 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 horse power output.

')

COUPLING SHAFT HIGH PRESSURE SEAL NEEDLE THRUST BEARING DRIVE LlNK12-TOOTH SPLINES

DIRT & WATER SEAL NEEDLE RADIAL BEARING

TorqmotofM MF Series features include: '- Roller vanes to reduce friction and internal leakage and to maintain efficiency.

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

-Wheel mount version available.

-More starting torque than competitive motors in applications where the shaft is side loaded. ICompetitive brands require more pressure to start the motor. 1 - A needle-roller mounted coupling shaft and steel-caged thrust bearing which can withstand lOOO-pound thrust loads.

-Side load capacity is 1600 Ibs 1727.3 kgl maximum at center of output shaft.

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

-Up to 17 horsepower output.

-Greater durability due to superior lubrication and minimum drive spline wear.

V -Patented 60-40 spline member arrangement transmits more torque wit~ less weight. /

MATCHED ROTOR SET MATCHED COMMUTATOR SET ~.,

)

(

MG, MF, MB, ME Series Service Procedure

)

(

Write or call for information and added details concerning your installation and applications:

)

Phone: Telex:

Write:

317.423.5377 279413 TRW Ross Gear Division 800 Heath Street lafayette, Indiana 47902

MG.MF.MB,ME 101 WA/SM 9-91

c)

(\

I, \

)

Disclaimer This Service Manual has been prepared by TRW Ross Gear Division 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. TRW Ross Gear Division 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 TRW Ross Gear MAB & MAE Torqmotor Units. However, despite the care and effort taken in preparing this general Service Manual, TRW makes no warranties that fa) the Service Manual or any explanations, illustrations, infnrmation, techniques or tools described herein are either accurate, complete or correct as applied to a specific Torqmotor unit, or fbi 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 MANUFACTURER'S SERVICE MANUAL ANO WARRANTY. 00 NOT TRY TO REPAIR OR SERVICE A TOROMOTOR UNIT WHICH HAS BEEN DAMAGED OR INCLUDES ANY PART THAT SHOWS EXCESSIVE WEAR UNLESS THE DAMAGED AND WORN PARTS ARE REPLACED WITH ORIGINAL TRW REPLACEMENT AND SERVICE PARTS AND THE UNIT IS RESTORED TO TRW'S SPECIFICATIONS FOR THE TORQMOTOR UNIT. It is the responsibility of the mechanic performing the maintenance, repairs or service on a particular Torqmotor unit to lal inspect the unit for abnormal wear and damage, fbi 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 Icl 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.

\) MAB and MAE Series Service Procedure

( \)

Write or call for information and added details concerning your installation and applications: Phone: Telex:

317.423.5377 279413

Write:

TRW Ross Gear Division 800 Heath Street Lafayette, Indiana 47902

MAB-E 109 WAl5M 8/88

II~;'. () TM

orqmotor

MAB and MAE Series Service Procedure

\)

TRW Ross Gear Division ().

Price $3.00

n Table of Contents Page

Trouble Shooting Guide ....................................................... 1A Exploded Assembly View Fold Out. ..................... " ..................... 1B.l C Trouble Shooting Checklist ..................................................... 10 Seal Installation Tools ..................... : .................................... 2 MAS Service Parts list Chart .................................................... 3 11 '/4 Inch, 31.8 mm, Seal Dia. Coupling Shaftl MAE (Standard) Service Parts List Chart. .......... '.' ............................... 4 (1'/4 Inch, 31.8 rnm, Seal Dia. Coupling Shaft) MAE Service Parts list Chart .................................................... 5 1Y2 Inch, 38.1 mm, Seal Dia. Coupling Shaft) Disassembly & Inspection ....................................................... 6 Assembly .................. '.' ............................................... ti

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Rnal· Checks ................................................................ 1() Hydraulic Auids ........................ , ..................................... 1() Filtration, Operating Temperature ................................................ 1() Tips for Maintaining the System ................................................. 11

lJ © TRW 1988

[~lVV/NEI

MODELS M18 & M20 (18 hp)

(20 hp)

CONGRATULATIONS-You have selected the finest four--cycle, twin--cylinder, air-cooled engine that money can buy. Kohler designs and builds long-life strength and on-tha-job durability into each engine ... making a Kohler engine the most dependable engine available ... dependability you can count on. Here are some reasons why:

• Parts subject to the most wear and tear (like the cylinders, crankshaft, and camshaft) are made from precision formulated cast iron. Because the cast iron cylinders can be rebored' these engines can last even longer.

• Dependable. maintenance-free electronic ignition system ensures fast, easy starts time after time.

:)

• Kohler engines are easy to service.

All routine service areas (like the dipstick and oil fill. air cleaner, spark plugs, and carburetor) are easily and quickly accessible.

• Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers-so service support is just a phone call away.

To keep your engine in top operating condition, follow the simple maintenance procedures given in this manual.

KOHLER

-------------------------------~ \.:::lU ~UU ~ ENGINE DIVISION. KOHLER CO .• KOHLER. WISCONSIN S3044

Recommended SAE 011 VIscosity Grade.

FUEL For best results, use only clean, fresh, regular grade unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method. it should be 90 octane minimum.

Unleaded is recommended since it leaves less combustion chamber deposits. Regular grade leaded gasoline may also be used; however. be aware that the combustion chamber and cylinder head will require more frequent service. See "Required Maintenance" on page 4.

Always use fresh gasoline. Fresh gasoline is blended for the season and reduces gum deposits which could clog the fuel system. Do not use gasoline left over from the previous season.

Do not add oil to the gasoline.

Do not overfill the fuel tank. Leave room for the fuel to expand.

AWARNING: Explosive Fuel Gasoline is extremely flammable, and its vapors can explode if ignited. Store gasoline only in approved containers, in unoccupied buildings, away from sparks or flames. Do not add gasoline while the engine is hot or running, or start the engine near spilled gasoline.

Never use gasoline as a cleaning agent.

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Straight 3Q-weight ollis recommended. If multlviscoslty oil is used in temperatures above 321'F (OOC) , be aware of the following: • I ncreased oil consumption and a corresponding increase in combustion deposits requiring more frequent cylinder head service.

• More frequent oil changes are required.

4. Add the proper type of oil if the level is low. Bring 1he level up to, but not over, the "F" mark on the dipstick. Always cn eck the level on the dipstick before adding more oil.

(See "Changing Oil", "Oil Filter", and "Required Maintenance" on pages 2.

3, and 4.)··

CAUTION: 00 not operate the engine with the oil level below "L" mark or over "F" mark.

CAUTION: Using other than service class SF oil or extending oil change intervals longer than recommended could cause engine damage which is not covered by the engine warranty.

A logo or symbol on oil containers identifies the API service class and SAE viscosity grade.

Checking

all

OIL

Check oil BEFORE EACH USE as follows:

Using the proper type and weight crankcase oil is extremely important as is Checking oil daily and changing oil and filter regularly. (See "Required Maintenance" on page 4.) Failure to use the correct oil or using dirty oil causes premature engine wear and failure.

1. Make sure the engine is stopped and resting on a level surface. Also make sure the engine is cool and the oil has had time to drain into the sump.

Before each start, make sure the crankcase is filled with proper type and quantity of oil.

2. Before removing the oil fill cap or dipstick, ciean the area around these parts to keep dirt and debris out of the engine.

all Type Use high-quality detergent oil of API (American Petroleum Institute) service class SF. Select the viscosity based on 1he air temperature at the time of operation as shown In the table.

3. Remove the dipstick and wipe oil off. Reinsert the dipstick and push it all the way down into tube. Remove the dipstick and check the level.

all SentryTIl

Some engines are equipped with optional Oil Sentry oil pressure monitor.

Ifthe oil pressure gets low, Oil Sentry will either shut down the engine or trigger a warning signal, depending on the application.

CAUTION: Make sure the cilleve' is checked· BEFORE EACH USE and maintained up to the "F" mark on dipstick. This includes engines equipped with 011 Sentry.

Changing

all

For a new engine, change oil after the first 5 hours of operation, and then as shown in the "Oil C/'\8nge Intervals" table.

011 Change Intervals Temperature ABOVE

011 Type SAE30

32' F (00 C) Multlvlscosity BELOW

32' F (00 C)

Multiviscosity

Engine Type

Interval

With Filter

50 hours·

Without Filter

25 hours

With Filter Without Filter

25 hours 25 hours

With Filter

50 hours 25 hours

Without Filter

·25 hours for continuous and/or heavy duty operation.

2

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Drain oil while the engine is warm from operation. The oil will flow freely and carry away more impurities. Drain oil as follows: 1. Remove the oil drain plug and oil fill cap. Tilt the engine Slightly towards the oil drain to obtain better drainage.

2. Reinstall the drain plug. Make sure it is tightened securely.

3. Fill with new oil of the proper type to the "F" mark on the dipstick.

Always check the level on the dipstick before adding more oil.

4. Reinstall the oil fill cap. Make sure it is tightened securely.

Make sure the engine is level when filling and checking oil.

011 Filter Some engines are equipped with an oil filter. Replace the oil filter every other oil change. in accordance with the "Oil Change Intervals" table on page 2. Always use a genuine Kohler oil filter. part 52 050 02, and replace as follows: '

1. Drain crankcase oil. then remove old filter.

2. Before installing replacement filter, apply a thin coating of oil on the surface of the rubber seal.

3. Turn filter clockwise until rubber seal contacts the fllter adapter, then tighten filter an additional 2/3 to 3/4 turn.

4. Add an additional 1/2 pint of oil for the filter capacity. See "SPECIFICATIONS" on page 8.

5. Start the engine and check for oil leakage.

OPERATING INSTRUCTIONS ALSO READ THE OPERATING INSTRUCTIONS OF THE EQUIPMENT THIS ENGINE POWERS.

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PRE-START CHECKLIST

a Check oil level. Add oil if low. a Check fuel level. Add fuel if low. a Check cooling air intake areas and

external surfaces of engine. Make sure they are clean and unobstructed.

a a

Check that the air cleaner components and all shrouds, equipment covers. and guards are in place and securely fastened.

Check that any clutches or transmissions are disengaged or placed in neutral. This is especially important on equipment with hydrostatic drive. The shift lever must be exactly in neutral to prevent resistance' which could keep the engine from starting.

AWARNING: Lelhal Exhaust

Ga••• Engine exhaust gases contain poisonolJs carbon monoxide. Avoid inhaling fumes. and never run the engine in a closed building or confined area.

I) STARTING 1, On A Cold Engine - Place the

throttle control MIDWAY between the "SLOW' and "FAST" positions.

Place the choke control into the "ON" position.

On A Warm Engine (Normal Operating Temperatures) - Place the throttle control MIDWAY between the "SLOW' and "FAST" positions.

Place the choke control into the "OFP' position.

2. Activate the starter switch. Release the switch as soon as the engine starts.

3. On A Cold Engine - Gradually return the choke control to the "OFF" position after the engine starts and warms up.

NOTE: After starting the engine, it may be necessary to leave the choke partially "ON" for a few minutes before moving it to the "OFP' position.

CAUTION: Do not crank the engine continuously for more than 10 seconds at a time. If the eng ina does not start, allow a SO-second cool-down period between starting attempts.

Fai/ure to follow these guidelines can burn out the starter motor.

CAUTION: If the engine develops sufficient speed to disengage the starter but does not keep running (a "false start"), the eng ine rotation must be allowed to come to a complete

stop before attempting to restart the engine. If the starter is engaged while the flywheel is rotating, the starter pinion and flywheel ring gear may clash, resulting in damage to the starter.

If the starter does not turn the engine over, shut off starter immediately. Do not make further attempts to start the engine until the condition is corrected. Do not jump start using another battery (refer to "BATTERY" belOW.) See your Kohler Engine Service Dealer for trouble analysis.

BATTERY A 12-volt battery with a rating of approximately 32-amp hours is normally used. Refer to the operating instructions of the equipment this engine powers for specific information.

If the battery charge is not sufficient to turn over the engine, recharge the battery.

CAUTION: Do not attempt to jump start the engine with another battery.

Starting with batteries larger than those recommended can burn out the starter motor.

Also see "BATTERY CHARGING" on page 5.

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OPERATING Optional spark arrestor mufflers are available from your Kohler Engine Service Dealer. Check your local laws and statutes regarding engine spark arrestor muffler requirements.

CAUTION: Donotoperatetheengine continuously at angles exceeding 300 in any direction. Engine damage may result from lack of lubrication. Also refer to the operating instructions of the equipment this engine powers. It may have more stringent guidelines as to angle of operation due to equipment design.

CAUTION: If debris builds up on air intake screen and other intake areas, STOP the engine immediately and clean. Obstructed air intake areas cause engine damage due to overheating.

AWARNING: Hot, Moving Parts The engine and exhaust system get extremely hot from operation. Do not operate the equipment with covers, shrouds, or guards removed. Keep hands, feet, clothing, and hair away from al/ moving parts. Do not allow the equipment to run unattended.

CAUTION: Do not tamper with the governor setting to increase the maximum engine speed. Overspeed is hazardous and will void the warranty.

AWARNING: Rop. Starling Pulley I. Not a Drive Pulley Do not use backup rope starting pul· ley as a drive pulley. Using starting pulley as a drive coule loosen flywheel fastener, resulting in bodily harm.

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STOPPING 1. If possible, remove the load by disengaging all PIO attachments.

2. Place the throttle control MIDWAY' between the "SLOW" and "FAST' positions. Allow tile engine to run for a minimum of 15 seconds; then stop the engine. ·Minimum engine speed of 2400 RPM.

MAINTENANCE INSTRUCTIONS These required maintenance procedures should be performed at the frequency stated in the table. They should also be included as part of any seasonal tune-up.

REQUIRED MAINTENANCE

FREQUENCY"

Clean Air Intake Screen ..............•..•..•..••.•.....•..•••..••• DAILY" Check Oil Level ...•...•....•...........•..•...•...••...•.....•.•• DAILY Fill Fuel Tank ..................•...•...•.......•.....•..•..•• As Required Check/Replace Fuel Filter ......•.......•.•...•••.•••.....••.• As Required Change Oil and Filter ...••.••.•.•.......•... As Specified on Pages 2 and 3 Service Foam Precleaner .•.•.•••.•..•..•...•.•....•.••....•.•••.•• 25 Hrs." Clean Coaling Fins and External Surfaces ..••.•.........•.••••..••• 50 Hrs. Check Paper Air Cleaner Element ................................ 100 Hrs." Check Spark Plugs ............... , .............................. 100 Hrs. Have Valve-Tappet Clearance Checked*" ....••..••......•••.•••••. 500 Hrs. Have Cylinder Heads Serviced"" .................................. 500 Hrs.t Have Starter Motor Drive Serviced"" ..••..•••••••.••••••.•..••.••. 500 Hrs.

AWARNING: Accidental Starts Before servicing the engine or equip· ment, always remoye the spark plug leads to prevent the fiIIngine from start· ing accidentally. Ground the leads to prevent sparks that could cause fires.

"Perform these maintenance pro· cedures more freq -.Jently when the engine is operated lJnder extremely dusty and dirty conditions.

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··Have a Kohler Engine Service Dea· ler perform these services. t250 hours when leaded gasoline and/or multiviscosity oil is used.

Identification Plate (On Engine Shrouding)

Electric ----Starter Air Intake Screen

4

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IGNITION SYSTEM This engine is equipped with a dependable electronic ignition system.

Other than periodically checking/replacing the spark plugs, no maintenance, timing, or adjustments are necessary or possible with this system.

In the event starting problems should occur which are not corrected by replacing the spark plugs. see your Kohler Engine Service Dealer for trouble analysis.

CAUTION: Do not apply 12-V DC-to kill terminal of ignition module as module will burn out.

See wiring diagram on page 7.

COOLING SYSTEM

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Every 50 operating hours (more often under extremely dusty or dirty conditions) remove cooling shrouds and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine which can cause improper cooling. Make sure cooling shrouds are reinstalled. Operating the engine without cooling shrouds will cause engine damage due to overheating.

AIR CLEANER This engine.is equipped with a highdensity paper air cleaner element.

Some specifications are also equipped with an optional oiled foam precleaner which surrounds the paper element.

Precleaner If so equipped, wash and reoil the precleaner every 25 operating hours (more often under extremely dusty or dirty conditions).

1. Remove wing nuts, air cleaner cover, element cover seals, and element cover.

2. Remove precleaner from paper element. Wash the precleaner in warm water with detergent.

3. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Air dry.

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4. Saturate precleaner in clean, fresh engine oil and squeeze out excess 011.

5. Reinstall precleaner over paper element.

Paper Element

2. Remove plugs and check condition. Incorrect spark plugs. worn or fouled plugs. cracked porcelain, or improper spark gaps can cause hard starting or engine mislire~

Every tOO operating hours (more often under extremely dusty or dirty conditions) check the paper element. Replace the element as necessary.

3.

1. Remove the precleaner (if so equipped) from paper element.

Do not clean the spark plugs in a machine using abrasive grit. Replace plugs when dirty or if reuse is questionable. See "SPECIFICATIONS" on page 8 for plug type.

2. 00 not wash the paper element or use pressurized air as this 4. Check gaps (0.025") using a wire will damage the element. Refeeler gauge. Adjust the gaps as place a dirty, bent, or damnecessary by carefully bending the aged element with a genuine ground electrode. Install the plugs Kohler element. Handle new and torque to 10-15 ft. lb. elements carefully. Do not Wire Gauge_..,.,,~. ~ use if sealing surfaces are bent or damaged.

3. With air cleaner disassembled, check the base. Make sure it is secured and not bent or damaged.

Also check the element cover, seals, and breather tube for damage or improper fit. Replace all damaged components.

~.025"Gap

CAUTION: Damaged or loose components could allow unfiltered air into the engine causing premature wear and failure.

4. Reinstall the paper element, precleaner, element cover, element cover seals, air cleaner cover, and wing nuts. Tighten wing nuts 1/2to 1 full turn after nuts contact cover.

Do not overtighten.

SPARK PLUGS Every 1000perating hours remove the spark plugs, check condition and reset gaps, or replace with new plugs as follows: 1. Before removing spark plugs, clean the area around base of plugs to keep dirt and debris out of engine.

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BATTERY CHARGING AWARNING: Dang.roul Acid,

Explo.'". Ga••• Batteries contain sulphuric acid. A void contact with skin, eyes, and clothing.

Batteries produce explosive hydrogen gas while being charged. Ventilate the area when charging the battery. Keep cigarettes, sparks, open flame, and other sources of ignition away from battery at all times. Keep batteries and acid out of the reach of children.

Remove a/l jewelry when working on battery.

CAUTION: Do not apply 12-V DC to kill terminal of ignition module as module will burn out.

See

~iring

diagram on page 7.

5

CARBURETOR TROUBLESHOOTING AND ADJUSTMENTS Carburetor adjustments should be made only after the engine has warmed up.

M18 and M20 engines are equipped with one of two types of carburetorsadjustable main jet type or the new fixed main jet type. The new fixed jet carburetors are being phased-in across the entire model line. The table below shows which engines were built with adjustable jet carburetors and which engines were built with fixed jet carburetors.

Model M18

M20

Adjustable Jet Serial No.

Fixed Jet Serial No.

1629500986

1629500996

And Earlier.

And Later.

Serial No.

Serial No.

1619504206

1619504216

And Earlier.

And Later.

The carburetor is deSigned to deliver the correct fuel-to-air mixture to the engine under all operating conditions. The main fuel and idle fuel adjusting needles on adjustable jet carbu retors are set at the factory and normally do not require further adjustment. On fixed jet carburetors, the main fuel jet is calibrated at the factory and is not adjustable".

The idle fuel adjusting needle is also set at the factory and normally does not need adjustment.

If, however, the engine is hard starting or does not operate properly, it may be necessary to adjust or service the carburetor. See your Kohler Engine Service Dealer for assistance.

Turning the adjusting needles in (clockwise) decreases the supply of fuel to the carburetor. This gives a leaner fuel-to-air mixture. Turning the adjusting needles out (counterclockwise) increases the supply of fuel to the carburetor. This gives a richer fuel-to-air mixture. Setting the needles midway between the lean and rich position will usually give the best results.

TROUBLESHOOTING If engine troubles are experienced that appear to be caused by the carburetor, check the following areas before adjusting the carburetor.

• Make sure the fuel tank is filled with clean, fresh gasoline.

• Make sure the fuel tank cap vent is not blocked and that it is operating properly.

• If the fuel tank is equipped with a shut-off valve, make sure it is open.

• If the engine is equipped with an in-line fuel filter, make sure it is clean and unobstructed. Replace the filter if necessary.

• Make sure the air cleaner element is clean and a/l air cleaner components are fastened securely.

If, after checking the items listed above, starting or engine operation problems exist, it may be necessary to adjust or service the carburetor. See your Kohler Engine Service Dealer for assistance.

To Adjust Carburetor: 1. With the engine stopped, turn the adjusting needles in (clockwise) until they bottom lightly.

Idle Speed Adjusting Screw

Main Fuel Adjusting ~Needle (Adjustable Jet Carburetors Only)

I

Adjusting Needle Main Fuel Idle Fu-" 1 Turn 2-1/2 Turns 1-1/4 TUirn

I

3. Start the engine- and run at halfthrottle for 5 tc) 10 minutes to warm-up. The engine must be warm before ma.dng final settings (steps 4, 5, 6, and 7).

4. Main Fuel Needle Setting: This adjustment is required for adjustable main jet carburetors only. If the engine is equipped with a fixed main jet carburetor, go to step 5.

Place the throttle into the wideopen or fast pOSition. !f possible, place the engine under load.

Turn the main fuel adjusting needle out (counterclockwise) from the preliminary setting until the engine speed decreases (rich). Note the pOSition of the needle.

Now turn the adjusting needle In (clockwise). The engine speed may increase, then it will decrease as the needle is turned in (lean). Note the position of the needle.

Set the adjustin!;} needle midway between the rich and lean settings.

5. Idle Speed Setting: Place the throttle control into the idle or slow position. Set the i<lle speed to 1200' RPM (t 75 RPM) by turning the idle speed adjusting screw in or out.

Check the speec:l using a tachometer.

6. Idle Fuel Needle Setting: Place Ule throttle into the idle or slow position.

Idle Fuel Adjusting Needle

6

Carbo Type Adl. Jet Fixed Jet

"NOTE: The actual idle speed depends on the ap plication. Refer 10 the equipment manufacturer's instructions for specific idle speed settings.

Adjust ~ Lean To Midpoint ~~ I I

'NOTE: M18 and M20 engines with fixed jet carburetors, operating at altitudes above approximately 6000 ft., may require a special "high altitude" main jet. See your Kohler Engine Service Dealer for further information.

2. Preliminary Settings: Turn the adjusting needles atut (counterclockwise) from ligl"ttly bottomed as follows:

CAUTION: The tip of the idle fuel and main fuel adjusting needles are tapered to critical dimensions.

Damage to the needles and seats in carburetor body will result if the needles are forced.

Turn the idle fuel adjusting needle out (counterclockwise) from Ule preliminary setting until the engirle speed decreases (rich). Note Ute position of the needle. (

)

Now turn the adjusting needle In (clockwise). The engine speed may increase, then it will decrease as the needle is turned in (lean). Note the position of the needle.

Set the adjusting needle midway between the rich and lean settings.

the idle speed must not exceed 1500 RPM. Typical idle speed is 1200 RPM". See step 5, 7. Recheck idle speed using a tachometer. Readjust speed as necessary.

FUEL FILTER Some engines are equipped with an in-line fuel filter. Visually inspect the filter periodically and replace when dirty with a genuine Kohler filter.

NOTE: To ensure best results when setting the idle fuel needle,

TROUBLESHOOTING When a problem occurs, do not overlook the simple causes. For example, starting problems could be caused by an empty fuel tank. The table lists some common causes of troubles.

Do not attempt to service or replace major items or any items that call for special timing or adjustment procedures (governor. valves. etc.). Have this work done by your Kohler Engine Service Dealer.

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Dirt Dirty Incorrect Engine Dirty Faulty Air In 011 Over- Filter Spark No Improper Fuel Fuef Line Screen Level Loaded Element Plugs Fuel

Problem

Will not start Hard Starting Stops suddenly Lacks power Operates erratically Knocks or pings Skips or misfires Backfires Overheats High fuel consumetion

X X X

X X X X

X X

X

X X X

X X X

X X X X

X X

X X

X

X X X X

X X X X

X

X X

X X X X

X

X

STORAGE

PARTS ORDERING

MAJOR REPAIR

If the engine will be out of service for approximately two months or more, use the following storage procedure: 1. Change oil and filter when engine is still warm from operation. See "Changing Oil" and "Oil Filter" on pages 2 and 3.

The engine Specification. Model, and Serial numbers are required when ordering replacement parts from your Kohler Engine Service Dealer. These numbers are found on the identification pla.te which is affixed to the engine shrouding. Include letter suffixes if there are any.

2. Drain fuel tank and fuel system (or run engine until fuel tank and fuel system are empty.)

Record your engine identification numbers on the identification plate illustration for future reference.

Major repair information is available in Kohler Engine Service Manuals.

However. major repair generally requires the attention of a trained mechanic and the use of special tools and equipment. Your Kohler Engine Service Dealer has the facilities. training. and genuine Kohler replacement parts necessary to perform the service. Check the Yellow Pages under ENGINES, GASOLINE.

3. Remove the spark plugs. Add one tablespoon of engine oil into each spark plug hole. Install plugs but do not connect plug leads. Crank the engine two or three revolutions.

4. Clean exterior surfaces of the engine. Spread a light film of oil over any exposed metal surfaces of engine to prevent rust.

MODEL DESIGNATION

KOHLER@~ HP

Model M18S for example: M indicates MAGNUM engine. 18 indicates the horsepower. A letter suffix designates a specific version as follows:

MOOELNO. SPEC. NO. SERIAL NO. REFER TO OWNER'S MANUAL FOR OPERA TlONI MAINTENANCE INSTRUCTIONS ANO SAFETY PRECAUTIONS,

Suffix

S G

tW' KOHLER CO/v'PANY

5. Store the engine in a clean dry place.

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X X

X X

X X X X

I~'

CAUTION: DO NOT CONNECT 12 V. TO IGNITION SYSTEM OR TO ANY WIRE CONNECTED TO IGNITION MODULE. The ignition system operates independently of the battery. starting, charging. and other auxiliary electrical systems. Connecting 12 V. to ignition module will cause damage which is not covered by the engine warranty.

• A Break-before-make type key switch is required to prevent damage to ignition module. Use Kohler key switch no. 25 099 02 or equivalent.

KOHLER INISCONSIN USA

a

Designates

Electric Start Tapered Crankshaft (Generator Application) Quiet Model

Optional Diode

Kill Switch or Off POSition of Key Switch·

II

i ., I I Air Gap l l_ J t

Ignition Module Spark Plugs Flywheel

7

...

SPECIFICATIONS Power Rating @ 3600 RPM ••••••••••••••••••.•••••.••••••••••. hp kw

ModeIM18 18 13.4

...odef M20 20 14.9

Displacement ..••••••••••••••••.•••••.•••......•...•.•••. cu. in. cc

42.18 691.3

46.98 769.8

Bore .••.....•.••.•.•..••••.•••.•.••..••.•.•••.......•••..••• in. mm

3.12 79.2

3.12 79.2

Stroke ••••. , •••••••••.••••••••••••.•••.•••••••••••••...••.•. in. mm

2.75 69.85

3.06 78.0

Compression Ratio ......•.•.••••.•.••.••.•••••.••.••.•••..••' .....

6.0:1

6.6:1

Approx. Weight .•..••.. " •.••.••.•.•• ~' .•....•..•.......•••.•. lb. kg

130 59.0

130 59.0

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Oil Capacity· ........................................ U.S. Quarts

1.5

1.5

I..

1.4

1.4

Spark Plug Type ............................ Champion®or Equiv.

AV15YC

AV15YC

Spark Plug Gap .•..••••••..••••••.•.•...••.•...••.•...••...•• in. mm

0.025 0.65

0.025 0.65

Spark Plug Torque ........••.•...•.•• " ........•.. , •..•..•. ft. lb.

Nm

10-15 14-20

10-15 14-20

Ignition Module Air Gap ...................................... in.

0.008-0.012 (.010 Nominal) 0.200-0.300 (.250 NOminal)

().OOa-o.012 (.010 Nominal) ().200-0.300 (.250 Nominal)

mm

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·For best results, fill to "F" mark on dipstick as opposed to adding a given quantity ot oil. Always check level on dipstick before adding more oil.

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For engines equipped with oil filter-an additional 1/2 U.S. pint (.24 L) of oil is required when oil filter is replaced.

LIMITED 2 YEAR MAGNUM ENGINE WARRANTY We warrant to the original consumer that each new MAGNUM engine sold by us will be 'ree from manu'acturi.,g defects in materials or workmanship in normal service for a period of two (2) years from date of purchase. provided It is Clperated and maintained in accordance with Kohler Co:s instructions and manuals.

Our obligation under this warranty is expressly limited. at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin. 53044, or at a service facility designated by us, of such part or parts as inspection shall disclose to have been defective.

EXCLUSIONS: This warranty does not apply 10 defects caused by casualty or unreasonable use, inctuding faulty repairs by others and failure to . provide reasonable and necessary maintenance.

The following items are not covered by this warranty: Engine accessories. such as fuel tanks. clutches, transmissions, po_r drive assemblies, and batteries, unless supplied or installed by Kohler Co.These are subject to the warranties, if any. of their manufacturers.

WE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL. OR CONSEOUENTIAL DAMAGES OF ANY KINO, including but not limited to labor costs or transportation charges in connection with the replacement or repair of defective parts.

ANY IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We ITIake no other express warranty. nor <is anyone authorized t~ make any in our behalf.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from stata to state.

TO OBTAIN WARRANTY SERVICE: Purchaser must bring the engine to an authorized Kohler service facility. For the facility nearest you, consult your Yellow Pages or write Kohler Co., Attn: Engine Warranty Service Dept., Kohler, Wisconsin 53044.

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ENGINE DIVISION, KOHlER CO., KOHLER, WISCONSIN 53044

~~~~~~~~WJ\WIWi~~~~ma~~~ FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA. CALL

1-800-544-2444 Litho in U.S.A.

K 4/87

TP-2202

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Model95W Multiple Disc Brake Service & Repair Manual

Part Number & Technical Information

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OPTIONS AND ORDER INFORMATION

f ~~5 I ~a...;:;....I a..:..::..-II..--Ii.,i~~~_ _T~O~R~QUE~

_M_OD_EL. ___

Torque Code

B068 B087 B097 B098 B127 8128

OUTPUT PLOT W -

Wheel Mount

OUTPUT SHAFT 8

-

= 8000 Ib-ins

= 9000 Ib-ins

== = = ==

10000 Ib-1ns

12000 Ib-ina 14000 Ib-ins 16000 Ib-ins

ReI.Press.{lnitialIFull) 240[300 3101390 350'/.435 350Z435 455Z570

PSI PSI PSI PSI PSI 455i'570 PSI

Torques Itated en -«:/ and at (O)PS! bcdc 1'f'IIIIIU....

Other torques and release preIIIUreB are C3'ICIIIGbIe. Values mown en ltandcl"d units.

1.500 ora X 1.500 Taper Per Foot

INPUT PLOT (See Page 10) A -

SAE·A· 2 Bolt and Modified 4 Bolt

fI1UT SHAFT 3 4 -

SAE 1·-6B Spline 14T 12/24 Spline

)

Model 95W Service Manual The Model 95W series Eskridge brake is a spring applied. hydraulicafly released. multiple disc, failsafe parking brake with side load carrying capability. The 95W is designed with dry bronze friction linings and as a .. failsafe" type operation.

All brakes are individually tested at the factory for function. leaks and static breakaway torque. Failsafe type brakes are tested to be assured they are in excess of 110% of the failsafe torque rating for the unit. A failsafe brake should be used when the only requirement is a minimum static holding torque.

Of course, temperature, wear and contamination of the friction plate surfaces may effect the performance of the brake and should be taken into consideration when specifying a reqUired torque rating. Care should be taken to avoid damaging the splines or mounting surfaces during installation

Installation NOTE: Before beginning installation procedures, visually inspect brake mounting flanges and shaft splines for damage due to poor handling during shipping. If damage is eKcessNe. do not use brake.

I. The 95W brake is supplied with the necessary o-rings or gaskets for mounting the brake to a motor. Use the gasket when mounting the hydraulic motor to the brake. The 95W is also supplied with a slotted jam nut and key for the tapered shaft.

The tapered output shaft conforms to SAE J50 I standards. \ ) 2. The 95W brake is designed as a "thru bolting" (4) bolt assembly. The mounting bolts must be long enough to go thru the brake and into the mounting tube or plate. The hydraulic motor can be mounted directly to the input side of the brake using either the 2 or 4 bolt SAE "A" bolt patterns.

NOTE: I. Use only grade 5 or better mounting bolts or hardware for mounting the brake and or motor.

2. Allow a minimum of 1/2" thread engagement when sizing assembly bolts 3. Torque all 112.. 13 bolts to 75 ft-Ibs. 4. The brake can be rotated to orient the bleed arid release ports as required.

5. Some installations may reqUire that the brake be released so it can be rotated to align bolt holes (see step 4 of installation instructions) for mounting.

3. Remove plastic protective plug from pressure port of brake and attach a pressure line with a 71 I6-20UNF-2S straight thread o-ring fitting.

4. Apply low pressure (20-30 PSI) to brake release port. Loosen hollow hex plug opposite of pressure port, just enough to allow hydraulic fluid to bleed from piston cavity. After air has been bled from brake, tighten plug.

MOTOR

)

~ ~ GASKET OR O-RING

/)

Disassembly: I. Place brake on a stable work. platform. input shaft down. Use assembly/disassembly tool number ESK - 95002. A drawing is available for use in manufacturing your own.

2. Remove Snap Ring (ITEM 17).

3. Remove the (4) Socket Head Cap Screws (ITEM 18) from output end of brake.

\)

4. Remove Cover (ITEM 14). This will expose the internal components of the brake. The Case Seal O-Ring ( ITEM 13), Input Bearing (ITEM 15) and Snap Ring (ITEM 16) will be attached to the Cover. Note the color, number and spacing of the Springs (ITEM 10) before removal from Piston (ITEM 7). Inspect springs for breabge, discoloration WId spring rate. ( Blue

colored springs have a spring load of 250 lbs. @ .180" compressed height.).

S. Removal of the Piston (ITEM 7) will require the use of an air pressure source, air gun with a small nozzle dp and o-ring port plugs. Procedure is as follows:

* Remove any plugs in the release and drain ports of the brake Case (ITEM

4). Using the air gun. blow all excess hydraulic oil from piston cavity. ( This will keep excess oil from blowing down into the friction plate cavity wher\ piston is removed.) . * Place one o-ring port plug in either brake release port. Place doth shop rag aver piston cavity and brake. Usi~ the air gun and small nozzle tip, blow air into the open release port. The air pressure will blow the piston up and out of the piston bore in the Case (ITEM .. ). .

6. Remove and inspect the a.Rlngs and Back-Up Rings {ITEMS 8. 9 • II • 12 )for wear and or damage. Note seal orientation before removal. Seals must be replaced if abnormal wear or damage is evident.

1. Remove Brake Shaft (ITEM I). Inspect splines and bearing journals for abnonnaI wear or damage.

8. Tum brake assembly over, which will fadlitate the removal of the Friction Plates (ITEM 5), Spacer (ITEM 3) and Separator Plates (ITEM 6). Friction plates should be replaced if oil soaked and or excessively worn (dry brakes only).

) 9. If damaged, the Bearing (ITEM 2) can be removed and replaced. Check for wear spots and or nicks on the sealing lips of the bearing seals.

NOTE: An major components should be washed in a degreosing solution with a final cleansing rinse in alcohol. Do not rinse friction plates!

Assembly: Parts must be dean and dry before assembly. VISUally inspect components for damage and abnormal wear. Brake operation should be tested during nonnal service operation. SerYice or inspection to the brake should be part of the nonnal service and maintenance schedule of the equipment or vehicle. Any loss of holding torque reqUires the removal, inspection and replacement of suspect components.

Assembly should be In revers. order of disassembly with the following additlonailnstructJons • I. Place brake Case (ITEM 4) on a stable work platform, output end down. If the Bearing (ITEM 1) has been removed, press new bearing into the Case (ITEM 4). lubricate the bearing and seals with a light coat of lithium grease.

2. Using the assembly/disassembly tool number ESK-9S002 to properly space the Case (ITEM 4) off the work surface, install the Brake Shaft (ITEM I). Push shaft downward thru bearing until end of shaft bottoms out in the assembly/disassembly tool 3. Install Spacer (ITEM 3), Separator Plate (ITEM 6) and Friction Plate (ITEM S) in exactly the same order as they were removed. There must always be a Separator Plate (ITEM 6) on top and bottom of the friction stack of plates. If a Friction Plate (ITEM S) is placed next to the Piston (ITEM 8) or a Spacer, the unit will overheat and seize up. Be altefill not to contcuninate the friction plate surfaces with dirt. gtecJ!e. or fluid 0(any kind. ( ) 4. If replacing Piston O-Rings (ITEMS 9 Be II) and Piston Back-up Rings (ITEMS 8 Be 11), be sure o-rings are nearest each other with back-up rings to the outside after installing onto Piston (ITEM 7). lightly lubricate piston bores. Take Celie not to get IubriaJnt onto friction pade. Gently slide piston into Case (ITEM 4) until larger o-ring touches case. Using a light to mealUm duty press, install piston completely into bore. This will squeeze the o-rings and back-up rings and set piston against: friction pack.

S. Place the Springs (ITEM IO) into the $pring pockets in the Piston (ITEM 7).

6. If removed, install Input Bearing (ITEM IS) and Snap Ring (ITEM 16) into Cover ( ITEM 14).

7. Install the Case Seal O-Ring (ITEM 13) onto pilOt of the COver (ITEM 14).

8. Set Cover (ITEM 14) on top of the piston, springs and input end of the brake shaft. Start four Assembly Bolts (112.13 x 1.50) (ITEM 18) thru the Case (ITEM 4) and into the Cover (ITEM 14) with your fingers. A light to medium duty press aln be used to push the cover down on to the al5e so the cover bolts aln be installed more easily. Alternately tighten assembly bolts 112 tum at a time until cover is tight against the case. Tighten bolts to 110 ft-Ibs of torque.

9. Install Snap Ring (ITEM 17) on to the Brake Shaft (ITEM I). If snap ring will not fit, lightly tap the opposite end of the brake shaft with a brass hammer. This will help seat the shaft onto the Input Bearing (ITEM IS).

. )

10. The brake is now ready for minor testing of fit, function and release pressure. Due to the complex equipment required. you will not be able to test the holding torque ofthe brake. To test release pressure, place the a-ring port plug in one of the brake release ports.

Using a hydraulic power source either a hand pump or port -a-power, pressurize the brake slowly to the advertised release pressure both initial and full DO NOT EXCEED 1000 PSI WITHOUT THE BRAKE BEING BOLTED TO THE GEARBOX OR A TEST FIXTURE. As you pressurize the brake, rotate the brake shaft at the output end. The brake shaft should begin to tum at the advertised initial release pressure (+ or • 2S PSI). There will be drag on the shaft. Increase the pressure slowly until the shaft spins freely. this is the full release pressure. As you pressurize the brake, look (or signs of leaks which would indicate that the o-rings or back-up rings were damaged during assembly.

11. Use only mineral based hydraulic oil to test and operate Eskridge multiple disc brakes.

Repair Kits, 95W Repair kits listed below ate for use with the model9SW multiple disc brake.

NOTE: Due to the tnQny combinations of torques and release pressute$ available for the 9SW. it is impossible to detail each style and supply a repoir kit for each inolVidual model. The information listed in this monual is representative of 0/1 9SW brakes. The repair kiu listed below will work with aU combinations of torque VI. release pressure. input mountings and friction plates. It is entirely possible to have "extra-l'atU lett over from the repair kits after you hcrve completed the repair or mointenance. If you ate not sure about what is required for your broke and its configuration. please contact Eskridge, inc sales or engineering deportment.

WARRANTY MULTIPLE DISC - FAILSAFE BRAKES ESKRIDGE, inc. ("Eskridge'') warrants to its original purchaser ("Customer'') that new component parts sold by Eskridge ("unit (s)". at the time of delivery

by Eskridge to the customer will be free of defects in material and workmanship and will confonn to standard speciftcations set forth in current Eskridge sales literature and to any custom specifications of the customer acknowledged in writing by Eskridge, subject to the following qualifications and limitations.

)

I.

Prior to placing warranted units in service. the customer shan provide proper storage such that foreign objects (e.g., rain or debris) cannot enter any unit via entry ports which are nonnally closed during operation.

2.

The customer must notify Eskridge in writing of any claim for breach of this warranty promptly after discovery of a defect and in any event prior to the tennination of the warranty period. which shall commence when a unit is shipped to the customer by Eskridge and shall expire twelve (12) months thereafter.

3.

This warranty shall not apply with respect to units which. upon inspection

by Eskridge. show signs of disassembly, rework. modification pr improper installation. mounting use or maintenance.

4.

Claims under this warranty will be satisfied only by repair of any defect(s) or, if repair is detennined by Eskridge- in its sole, absolute and uncontrolled discretion to be impossible or impractical, by replacement of the unit or any defective part thereof. No cash payment or credit will be made for defective materials or workmanship. IN NO EVENT SHALL ESKRIDGE BE LIABLE FOR INODENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND OR NATURE.

s.

From time to time, Eskridge may make design changes in the component parts manufactured by it without incorporating such changes in units previously shipped.

6.

All freight charges in units returned for warranty service are the responsibilty of the customer.

THE FOREGOING WARRANTY IS THE SOLE W~R.RANTY MADE BY ESKRIDGE WITH RESPECT TO ANY UNIT. AND IS IN liEU OF ANY AND ALL OTHER WARRANTIES. EXPRESSED OR IMPLIED. wiTHOUT UMITING THE GENERAliTY OF THE FOREGOING, ESKRIDGE EXPRESSLY DISClAIMS ANY IMPLIED WARRANTY OR MERCHANTABIUTY OR FITNESS FOR ANY PARTICULAR PURPOSE. REGARDlESS OF ANY KNOWl.EDGE ESKRIDGE MAY HAVE OF ANY PARTICUlAR. USE OR APPLICATION INTENDED BY THE PURCHASER. THE SUITABILITY OR FITNESS OF THE UNIT FOR THE CUSTOMERS INTENDED USE. APPlICAllON OR PURPOSE AND THE PROPER METHOD OF INSTALLATION OR MOUNTING MUST BE DETERMINED BY THE CUSTOMER.

9SW SERVICE MANUAL

va· 3191

)

--

ISKILIDIiI

1900 KANSAS CITY RD. OLATHE, KS 66061 (913) 782-1238 (913) 782-4206 FAX

)

D/H/M Series Pumps, Fixed Gear Rotary Shaft Seal

~"

)

Driven Shaft

Quick Reference Data Chart Pump Series

Displacement IN3 fREV.

@ 1000 RPM In GPM

Weight In Pounds

0

.11 - .63

.5 - 2.7

2-3

H

.47 - 2.15

2.0 - 9.3

5-7

M

2.08 - 3.25

9.0 - 14.1

11 - 13

Pump Delivery

Fluid Compatibility All data based on Petroleum

~,'

0 ••

)

• Water Base Fluids Water Glycols Water Emulsions • Pressure ratings reduced to 1/2 specified ratings of model • RPM reduced by 1000 from specified rating of model • Always use "DU" bushings • Use Nitrile (Buna "N") seals

• Synthetic/Special Fluids Transmission Fluid Brake Fluid Diesel Fluid Mineral Oil Fluids • May need to de-rate based on viscosity • Use Nitrile (8una "N") seals

• Phosphate Ester Fluids Pydrauls. Skydrols. Cellulubes (Fyrquel). etc.

• Use pump as rated • Use Viton seals • Quintrolubic Fluids require "DU" bushings

Fluidpower Pump Division Otsego, MI 49078

ParDr Fluidpower

(

(

D/H/M Series Pumps, Fixed Gear

Features • • • • • •

Efficient. simple design - few moving parts Exceptionally compact and lightweight for their capacity Efficient at high pressure operation Resistant to cavitation effects High tolerance to system contamination Reliable under cold weather operation

Specifications

• •

• • •

r' )

185°F. Maximum operating temperature 10" Mercury maximum vacuum (at 1800 RPM) 5" Mercury maximum vacuum (at maximum rated RPM) 20 PSI maximum positive pressure Pressure to 2500 PSI

Fluid Viscosity • •

80-1000 SSU Operating viscosity range 4,000 SSU Maximum start-up viscosity

Filtration And Installation For maximum pump and system component life. the system should be protected from contamination at a level not to exceed 214 particles greater than 10 microns per milliliter of fluid.

Pump and motor shaft alignment must be within 0.007 inches total indicator reading using a standard float coupling. Please follow coupling manufacturer's recommended installation instructions to prevent end thrust on pump shaft. Tum pump by hand to assure freedom of rotation. Pump and motor must be on a rigid base.

The coupling should be sized to absorb the peak horsepower developed.

Fluidpower Pump Division Otsego, MI 49078

- ............ Fluidpower 5

D/H/M Series Pumps, Fixed Gear Instructions for Reversing Gear Pump Rotation The basic tools needed are a vise. preferably with soft jaws. a torque wrench. a thin screwdriver. a small hone stone. a ratchet. and a paper clip. The "0" series will require a 112" socket. the "H" series an additional 114" hex head driver, and the "M" series a 5/16" hex head driver. It is also recommended that you have on hand a tew extra heat shields and gaskets. Part numbers are 655287 and 655288 for the "0" series, 656942 and 656943 for "H" series, and 656026 and 656025 tor the "M" series.

To change rotation, hold the pump by the rear cover with the drive shaft painting up. Remove aU the bolts. The "0" series will have four hex head, the "H" series will have six hex and two allen head, and the "M" series will have eight allen head bolts. At this time, it would be helpful to scribe a line down the outlet side of the pump. If not marked. the outlet port is usually the smallest.

If the pump has a key type shaft, remove the key and hone down any burrs that may be on the shaft. This is important as the next step will be to lift off the front cover and any sharp edges could possibly damage the front seal or bearing.

After the front cover is off, note the position of the little vent hole in the bronze wear plate, which should have come off with the front cover. The parts underneath also have a similar vent hole. .

Remove in order, the wear plate, the heat shield, gasket. and V-seal. To facilitate this, make a little hook with a paper clip and lift up the part high enough to slip a screwdriver under and carefully pry up. Please note, the heat shield, in particular, is very brittle and may crack if bent.

After removing these four parts, reinstall the V-seal with the lips down in the front cover so that the vent hole is on the oppOsite side across from the reference mark. Use the screwdriver to seat it completely. Next instaU the gasket, heat shield, and wear plate; again with the vent hole in line with that of the V-seal. The wear plate should be almost flush with the surface of the front cover. You may have to go back and tuck in, here or there, so that it is flush.

Remove the center section and note the notch cut on the inside. This will be installed in line and next to the vent hole in the wear plate. The dowel pins used to locate the center section may be removed temporarily to facilitate sliding the center section over the gear assemblies. Be careful not to pinch the a-ring between the front cover and center section. If it doesn't want to stay in place, it can be "glued" using heavy grease.

Fluidpower Pump Division Otsego. MI 49078 6

1. Shaft Seal 2. Cap Screws 3. Hex Screws 4. Washers 5. Front Cover 6. V-Seal 7. Dowel Pins 8. Gasket 9. Heat Shield 10. WearPlate 11. "0" Rings 12. Center Section

14. Driven Gear Assembly 15. Flow Control ("H" Flow Divid« PumpQn~)

16. Relief Valve ("H" Flow Divider PumpOn~)

17. Back Cover 18. Thrust Plate (H&M ~)

19. 1<ey (Where Req\lired)

13.DriveGear~b~

If the pump is an "H" or "M" series, instaU the.bronze thrust plate into the center section orienting the side witl1 the bar in line with the vent hole.

The rear cover is installed with the outlet side in line with the vent hole. The outlet side will be marked or can be iden· tified by the smaller cavity internally. As when installing the center section, be careful not to pinch the a-ring seal.

To check your work. the line that was originally scribed on the side should now be located 180 0 on the rear cover and center section from that on the front cover.

Install the bolts and snug them down by hand. "Then torque to the proper setting, alternating from side to side. The correct torque specifications are 355·375" Ibs. for the "M" series, and 190-210" Ibs. for the "0" and "H" series . respectively.

Testing Procedure After pump has been reinstalled, run for 2-3 minutes before pressurizing. Try to apply pressure gradually for an addi· tional five minutes. but do not pressurize for longer than 5 seconds at a time.

Parker Fluidpower

)

",••

~.-.

TM

orqmotor

. MAB and MAE Series Service Procedure

\)

TRW Ross Gear Division

Price $3.00

Table of Contents Page

Trouble Shooting Guide . ........ .

Exploded Assembly View Fold Out .. .

..........

............... . ........ ........ .. .......

Trouble Shooting Checklist . ....... .

...... .

Seal Installation Tools ........... '. . .............. .

. ................ 2 . .3

MAE IStandard} Service Parts list Chart .......... .

11 Y4 Inch, 31.8 mm, Seal Dia. Coup I

......... 4

MAE Service Parts List Chart ........ .

1Yz Inch, 38.1 mm, Seal Dia. Coupli

....... 5

Disassembly &Inspection . . . . . ...... .

...... 6 ........

..

. .......... ......... 108

..........

Final Checks '" .............•.... '. ............ ...... . .... . ..........

Hydraulic Fluids. . . . . . . . . . . . ........ " ......... . . .......... .. ............ "

Filtration, Operating Temperature ......... .

Tips for Maintaining the System . . . . . . . ..

. .. 18,1C 10

..............

MAS Service Parts List Chart ..... " .

11 Y4 Inch, 31.8 mm, Seal Dia. Cou

Assembly ....................... " ........•

..... 1A

. ....... 10

)

. ............. 10 ......... 11

) © TRW 1988

Troubleshooting Guide )

NOTE: Before troubleshooting any system problem, check service literature published hy the equipment andlor component manufacturers. Follow their instructions, if given, for checking any component other than the MAS or MAE Torqmotorr- unit.

Preparation

Hydraulic Components

Make your troubleshooting easier by preparing as follows:

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

• work in a clean, well-lighted place; • have proper tools and materials nearby; • have an adequate supply of clean petroleum-bas~d solvent.

WARNING: SINCE THEY ARE FLAMMABLE. BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMAll EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. '/vARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR :JRESSURE REQUIREMENTS.

Preliminary Checks

I )

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

Next, go to the reservoir clOd 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 MAB and MAE system.

Visually check other components to see if they are loosely mounted, show signs of leaks, or other damage or wear.

Hydraulic systems are often trouble-free. The problem an operator complains of could be caused by something other than the hydraulic components.

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:

Thus, once you have determined that a problem exists, stan with the easy-to-check items, such as:

• oil seal leaks • loss of efficiency such as speed and torque

•

pans 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.

• pump loss of efficiency • pump failure • hoses become hard and brittle • hose failure A normal temperature range "!eans an efficient hydraulic system. Consult the manuals published by equipment and/or component manufacturers for maximum allowable temperatures and hydraulic tests that may be necessary to run on the performance of the hydraulic components. The MAB and MAE are not recommended for hydraulic systems with maximum temperatures above 2000f '93.3OCI.

lA

"Not used on all units.

NOTE: Assemble Seal Flat Side Out as Sbown in Enlarged View 01 Sectioned Segments 01 Items Number 19 and 20.

Item No.

:1

2.

3.

4.

5.

6.

7.

•7.1 B. BA. 9.

10.

11. llA.

liB.

I1C. l1U.

lIE.

11F. 12.

13.

Seal Re tailling Ring Back·Up Wasber Washer Seal HOUSIng

Seal Ring 121 Back Up Ring 121 Thrust Washer lhrust Washer 1111 usl Beallng Bearing Coupling Shalt Key Nut Washer Bult Lock Washer Retalmng Ring Bearing Thrust Bearing

14.

15.

16.

16A 168.

Hle

17 . lB. 19.

20.

21 22.

23.

24.

25.

26.

n 28.

2BA.

Olive lJllk Wear Plate Rotor Set Rotor Vane 171 Stator Manilold Plate Manifold Commutator Seal Ring Commutator Ring Sleeve End Cover Assembly Special Boh III Plug o Ring Spllng 121

Valve IShulllel Reliel Valve 121 ITwo piece'

...,

Alter...e COIIltruetio.

Rellel Valve Elld Cover

"

/'2.1

V

Alternate Construction" shullie valve end cover -, NOTE: "Alternate Construction" is lor Torqmotorsnotlisted in cbarts provided in tbis manual. .,

"<

28

'27

~/ /26 ,

0

/25

•

MAD/MAE Torqmotor™ Exploded Assembly View-Typical (Identical to page 18)

/

/

&

/~/

IS 16.B

1b.A 1b.C/

Matched Set lor NOTE: Assemble Seal Flat Side Out as Shown in Enlarged MAB TorqmolOrs View 01 Sectioned Segments of Items Number 19 and 20.

Item No.

:12,

3.

4.

5.

6.

1.

'7.1 B. HA.

!I.

m 11. llA. 110.

liC. 1l0. llE.

llf.

12, 1J

Seal Retaining Ring Back·Up Washer Washer Seal HouslRg Seal Ring t2I Back Up Ring 121 Thrusl Washer 1I1IIIsi Washer IIl1l1sl Bearing Beming Coupling Sha It Key

14.

15.

16, 16A 16B. 16C.

11.

18.

19.

20.

n

22.

23.

24.

NUl

25

Wa~hm

21i.

27.

2B. 2BA.

Bllh lock Washer Relalnlng Ring Bcaring Thrusl Beallng

OliVO llRk Wear Plale ROlor Sel ROlor Vane 171 Slator Manilold Plale Manilold Curnrnutalor Sual RillY Commulalor Ring Sleeve End Cover Assembly Special Boll I1t Plug o Hing , Spring 121 Valve IShulllel Reliel Valve !Two piece)

m

I

"r~'

,/

~

-6

• ~7'1* //l ~

MATCHeD

S

".4W

°0

16

CJ:.SET)

/

·Not used on all units.

0c//3, o //5

~A, iI .

1* 2

"_~CHfD

/ "/'i

18

/

G

®4~" //9 ./ ~

AII.rnale ConSlruction R.U., Valve end Cov.r

.....:

~~>

llE

0// SA '\' \~'A o ./ ~"A O~ ~.

8

110

/10

11F

II

~/12 ~//'

'~'II!

~

u .... ,{ : ... ' "

0,(,

21/

"

/27

V

Alternale Construction" 28 shultle valve end cover -~ 27 NOTE: "Allernate Construction" is lor Torqmolorsnol/isled in ..... / /26 charts provided in this manual. .... O· /25

•

./

Troubleshooting Checklist

Seal Installation Tools 1.185 1.175 '.780 .740

2.370 2.360 2.280 2.240 2.052 2.057

POLISH TO REMOVE SHARP EOGE ONt Y

Dimensions Shown in InclIas

Tool No. J26751 J33074-1

Shaft Seal Dia. l'A 1Yz'

Dim. "A" 1.25211.258 1.50211.508

Dimensions Shown in indies Dim. "8" 1.290/1.280 1.54011.530

Tool No. J26753 J33074-3

Seal Thimble Figure 1.

Shaft Seal Oil. 1%

Dim. "A" 1.502/1.504 1.751/1.753

1Yt

1.240 1.280

==n

-A·OIA -B"OIA

Inches .740 .760 1.175 1.185 1.240 1.252

1.258 1.260

1.280 1.290 1.300 1.350 1.498 Dimensions Shown in 1nches Dim. "A" 1.30011.350 1.55011.600

"e"

CONVERSIONS

4.00 3.00 3.10

Tool No. J26752 J33074-2

Oim.

1.59011.610 1.84011.860

Seal Compression Ring Figure 3.

4.10

Shaft Seal Dia. 1% lYz

Dim. "8" 1.73511.115 1.98511.965

Dim. "8" 1.50011.498 1.74711.145

1.500 Dim. "C" 1.80011.600 2.40012.200

Seal Driver Figure 2.

1.502 1.504 1.508 1.530 1.540

1.550 1.590 1.600

mm 18.80 19.30 29.85 30.10 31.50 31.80 31.95 32.00 32.51 32.77 33.02 34.29 38.05 38.10 38.15 38.20 38.30 38.87 39.12 39.37 40.39 40.46

Inches 1.610 1.115 1.735 1.145 1.747 1.751 1.753 1.800 1.840

1.860 2.052 2.057 . ·2.200 2.240 2.260 2.360 2.370 2.400 3.00 3.10 4.00 4.10

mm 40.89 43.55 44.07 44.32 . 44.37 44.48 44.53 45.72 46.14 47.24 52.12 52.25 55.88 56.90 57.40 59.94 60.20 60.96 76.2 78.1 101.6 104.1

NOTE: Tool Kit J26905 for 1" inch (32 mm) seal diameter coupling shaft includes tools J26751, J26752 and J26753.

Tool Kit J33074· for 1~ inch (38 mm) seal diameter coupling shaft includes tools J33074-1, J33074·2 and J33074-3.

Tool Kits available from: Kent·Moore, 29784 tittle Mack, Roseville, Michigan 46066, Phone (313) 774-9500.

2

c:.l

MAB Service Parts List Chart (1 %Inch, 31.8 mm, Seal Dia. Coupling Shaft) CHART USE EXAMPLE: MAB06002 TOROMOTORTM INCLUDES PART NUMBERS USTED TO THE RIGHT Of MAS, 06- AND ·002 SHOWN IN LEFT HAND COLUMN OF CHART. CAUTION: THE CHARTED COMPONENT SEflVICE INFORMATION IS FOR THE TOROMOTORS LISTED ONLY. REFER TO THE ORIGINAL EOUIPMENT MANUFACTURER OF THE EOUIPMENT USING THE TOROMOTOR FOR ASSEMBlY NUMBERS NOT LISTED BElOW.

MAB

MAB

MAB

06· 08· 1014· 1624· 32·

-002 ·003

-004 ·005 -008 ·009 -010 ·011 ·014 ·015 ·016

·011 ·041

EXPlODED VIEW ITEM I DESCRIPTION SERVICE PART I EXPLODED VIEW ITEM I DESCRIPTION SERVICE PART I EXPLODED VIEW ITEM I DESCRIPTION SERVICE PART I EXPLODED VIEW ITEM I OESCRIPTION SERVICE PART I SERVICE PART I SERVICE PART I SERVICf PART I SERVICE PART I SERVICE PART I SERVICE PART I EXPLODED VIEW ITEM ...

DESCRIPTION SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICf PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I

l' Seal 032436

2" Retaining Ring 401346

8 & 8A" Theust Washer(2) 400103

S"

10"

12"

Thrust Bearing 061029

Baa' 07u582

Bearin8 0705""1

11+18 Manifold Plate + Manifold MABOI5003Xl

19+21 Commutetor Assy.

MAB01BOOOSl

20' Seal Ring 032435

23 End Cover AssV. MABO 16000A 1

14 Drive Unk MAB083001 MAB083001 MAB 103000 MAB143000 MAB 163001 MAB243001 MAB323001

16 Rotor Set MAB067001A 1 MAB087000A2 MAB107000A1 MAB 147000A1 MAB167000A2 MAB247000A3 MAB327005A 1

22 Slaeve 099025 099025 099091 099104 099026 099024 099085

24 Spacial Bokl7l 021270 021270 021270 021326 021271 021272 021273

6

11 Coupling Shaft 091399 091404 091404 091399 091405 091405 091418 091418 091482 091937 091482 091437 091435

1tA Kev

11B'" Nut

039027 039027

025126 025126

Housing MABOI200OA 1 MABOI2002Al MAB012000Al MAS012002Al MABOl200OA1 MA8012002A 1 MAB012000Al MAB012002Al MAB012002A 1 MABOI2000At MABOl2000A 1 MABO 12002A1 MAB012000Al

3' Back·Up Washer 028398

039028 039028

4' Washer 029106

6'

r

Seal 032633

Seal Ringl21 032519

13" Thrust Bearing 067031

15 Wear Plate ~"237

llC Washer

110 Bolt

lock Washer

028413 028413 028413

6223734 6223734 6223734

6103325 6103325 6103325

028413

6223734

6103325

HE

l1f Retaining Ring

401333 401333

NOTES:

-Indudad in MAB500003-standard seal kit Other kits: MA8500004-viton, synthetic lIuid applications, MAB500005-cold temperature applications.

"Included with item 16, Service Housing Assembly. "'Item 1118 nul sarvice perl number listed is for Torqmotor assembly pert numbers with en At suffIX only.

Item 1118 nut service pert numbel for Torqmotor essembly pert numbers with en A4 suffix is 025113.

Item 1118 nut service part number for Torqmotor assembly part numbers with en A7 suffix is 025132.

(\ .~

<~

~

.-....

\.-,.

U MAE (Standard) Service Parts List Chart (1 %Inch, 31.8 mm, Seal Oia. Coupling Shaft)

~

CHART USE EXAMPLE: MAE·l0002 TOROMOTOR™ INCLUOES PART NUMBERS LISTED TO THE RIGHT OF MAE. 10· AND ·002 SHOWN IN LEFT HAND COLUMN OF CHART. CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TORQMOTORS LISTED ONLY. REfER TO THE ORIGINAL EQUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TORQMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BELOW.

MAE

MAE

10· 14· 20· 24· 34· 68·

·002 ·003

·004 ·005 ·008 ·009 ·010 ·011 ·014 ·015 ·016 .(J17

·029

EXPLODED VIEW ITEM' OESCRIPTION SERVICE PART' EXPlODED VIEW ITEM' DESCRIPTION SERVICE PART , EXPlOOED VIEW ITEM I DESCRIPTION SERVICE PART , SERVICE PART , SERVICE PART , SERVICE PART I SERVICE PART I SERVICE PART , EXPLODED VIEW ITEM ....

DESCRIPTION SERVICE PART , SERVICE PART , SERVICE PART I SERVICE PART , SERVICE PART , SERVICE PART , SERVICE PART , SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART , SERVICE PART I SERVICE PART I

l' Seal 032436

2' Retaining Ring 401393

3' Back·Up Washer 028398

4' Washer 029106

5' Seal 032633

r Seal Ringl21 032519

8 & BA"

S··

Thrust Washerl21 400103

Thrust Bearing 067029

10" Bearing 070502

12'" Bearing 070501

13" Thrust Bearillg 067031

19+21 Commutator AssV. MABOI8000S1

20' Seal Ring 032435

14 Drive link MAE 103000 MAE 143000 MAE203000 MAE243000 MAE343000 MAE683000

15 Wear Plate 477259 477259 477259 477259 477257 477257

16 Rotor Set .MAE107000 MAE147000 MAE207000 MAE247000 MAE347000 MAE687000

11 Manifold Plate 477260 477260 477260 477260 477256 477256

18 Manifold MAE015000 MAE015000 MAEOl5000 MAEOI5000 MAB015003 MABOI5003

22 Sleave 099082

End Cover Assv.

099096

6 Housing MABOI2000Al MABOI2002A 1 MABOI2000A1 MABO12002A1 MABOI2000A 1 MA8012002A 1 MABOI2000A 1 MA8012OO2A 1 MA8012002Al MAB012000A 1 MAB012000A 1 MABOt2002Al MASOI2007A2.. ••

]1 Coupling Shaft 091443 091442 091442 091443 091445 091445 091441 091441 091453 091452 091453 091452 091460

llA Key

11B'" Nut

039027 039027

025126 025126

039028 039028

039027

23

099064 099079

MAE016000A 1 MAE016000A1 MAEOl6000Al MAE016OOOA1 MAB016OOOA1 MAB016OOOA1

24 Special BoItl71 021271 021352 021340 021273 021273 021329

l1C Washer

110 Bolt

HE Lock Washer

l1F Retaining Ring

028413 028413 028413

6223734 6223734 6223734

6103325 6103325 6103325

401333 4013"

028413

6223734

6103325

025126

NOTES; •Included in MAB500003-standard seal kit. Other kits: MAB500004-viton. synthetic fluid applications; MAB500005-cold temperature applications.

• 'lncIuded with item 18, Sarvice Housing Assembly. : ' •• ·ltem 111 B nut service part number listed is for Torqmotor assembly part numbers with an A1 suffix oniV. Item I11Q ,nut service pari number for Torqrnotor assembly part number. witll an A4 suffIX is 025113.

Item I11B nut sarvice pari number tor Torqmotor assembly part number with an Al suffix is 025132. ····Housing MAB012007A2 uses chamfared washer #400135 for item 8A in the exploded assembly view.

099092

099066

(JI

MAE Service Parts List Chart (1 %Inch, 38.1 mm, Seal Dia. Coupling Shaft) CHART USE EXAMPLE: MAE10037 TOROMOTORTM INCLUDES PART NUMBERS LISTED TO THE RIGHT OF MAE, 10· and ·037 SHOWN IN LEFT HAND COLUMN OF CHART. CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TOROMOTORS LISTED ONLY. REFER TO THE ORIGINAL EQUIPMENT MANUfACTURER OF THE EQUIPMENT USING THE TOROMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BELOW.

MAE

MAE

10· 14· 20· 24· 34· 68·

·037 ·038 ·039 ·040 ·048

EXPlODEO VIEW ITEM I DESCRIPTION SERVICE PART I EXPLODED VIEW ITEM I DESCRIPTION SERVICE PART I EXPlODED VIEW ITEM I DESCRIPTION SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I SERVICE PART I EXPlODED VIEW ITEM I DESCRIPTION SERVICE PART # SERVICE PART # SERVICE PART I SERVICE PART I SERVICE PART I

l' Seal 032752

2' Retaining Ring 401431

3' Back-Up Washer 028475

4' Washer 029107

5' Shah Seal 032726

7* Seal Ring 121

0" Thrust Washer 400136

8A" Thrust Washer 400138

S" Thrust Searing 069017

10&12" Bearing(21 071017

13" Thrust Bearing 068024

19+21 Commutator A:ssy.

MABD 1BMOs I

20' Seal Ring 032435

14 Drive link MAE 103000 MAE 143000 MAE203000 MAE243000 MAE343000 MAE683000

15 Wear Plate 477259 477259 477259 477259 477257 477256

16 Rotor Set MAE 107000 MAE 147000 MAE207000 MAE247000 MAE347000 MAE687000

17 Manifold Plate 477260 477260 477260 477260 477256 477256

18 Manifold MAE015000 MAE015000 MAE015000 MAEOl5000 MAB015003 MABOl5D03

22 Sleeve 099082 099096 099092 099066 D99064 099079

23 End Cover Assy.

MAEOl6000Al MAEOl6000Al MAEOl6000Al MAE016000A1 MABOI6000A 1 MABOI6000Al

6 Housing MABOI2D15Al MAB0120t3A 1 MAB012014A 1 MAB012014A 1 MAB012015Al

11 Coupling Sheft 091468 091466 091466 091468 091466

11A Key 039039 039027 039027 038039 038027

l1S'" For A1 Assys.

Nut 025131 025126 025126 025131 025126

11 B'" For A4 Assys.

Nut

118'" For A7 Assys.

Flut

025113 025113 025133 025113

025132

NOTES: 'Included in MAE50000J-Slandard seal kit.

"Included with item 16, Service Housing Assembly. "'ltem 111B nut service part number varies as shown for Torqmotor assembly part numbers listed that have an A1, A4 or A7 suffix.

O:J2519

24 Special BoItl71

021271 021352 021340 021213 021213 021329

Disassembly and Inspection Procedures two retaining rings to select from.! Apply a small amount of clean grease to the back side of new seal 111 and assemble into housing ~61 if required.

PREPARATION BEFORE DISASSEMBLY Before disconnecting hoses, thoroughly clean off all outside dirt around fittings. (After disconnecting hoses and before removing from vehicle, 1M MEOIATELY plug portholes.! Drain fluid and finish cleaning and drying assembly before placing on a clean work surface. (A piece of clean paper makes an excellent disposable top.! All disassembled parts should be cleaned separately in clean petroleum-based solvent and blown dry with air to avoid nicks and burrs. Discard a/l seal and seal rings as they are removed from Torqmotor. Use Ross Gear Division or OEM approved service parts.

WARNING: SINCE THEY ARE flAMMABLE, BE EXTREMEl Y CAREFUL WHEN USING ANY SOLVENT. EVEN A SMAll EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH.

TOROMOTOR DISASSEMBLY IReference Exploded Assembly Viewl 1.

WARNING: IF THE TQROMOTOR IS NOT FIRMLY HElD IN THE VISE, IT COULD BE DISLODGED DURING THE SERVICE PROCEDURES, CAUSING INJURY. 2.

If the end cover assembly (23) has a shuttle valve 1281, scribe a line on housing 161 in some manner in line with the port in the end cover for reassembly orientation. loosen the two plugs (25) with a 3/16 or 3/8 inch Allen wrench, for later disassembly. Remove the seven special bolts (24) using a 9116 inch thin wall socket. Inspect bolts for damaged threads, or the sealing ring under the bolt head. Replace damaged bolts.

3.

Remove end cover assembly 123) and seal ring 171 and back up ring 17.1) if included by inserting screwdriver between end cover assembly and sleeve (221. Pry up end cover assembly and lift from unit with rings attached. Discard seal ring and back up ring. It may be necessary to use a chisel and hammer to break the end cover loose.

4.

If the end cover 1231 has shuttle valve'1281 or relief valve 128AI and the previously loosened plugs (25), remove the two plugs and a-rings 1261.

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.

REPLACEMENT OF HIGH PRESSURE SEAL (5) WITHOUT COMPLETE TORQMOTOWM DISASSEMBLY lAeference Exploded Assembly Viewl

1.

Remove and discard dirt seal III and retaining ring 12) from Torqmotor. [Some applications may not require dirt seal 111.]

2.

Completely fill Torqmotor with oil. Plug "A" and "B" ports and set Torqmotor in a clean pan. Place a clean rag around the coupling shaft seal area of the housing to prevent oil spray. Carefully grip coupling shaft with appropriate wrench and rotate coupling shaft rapidly in a counter-clockwise direction. Oil pressure generated by Torqmotor will eject backup washer 13), washer (41 and seal 151.

3.

4.

)

CAUTION: Be ready to catch two springs (27) and shuttle valve (28) or relief valve (28A) that will fall out of the end cover valve cavity when the plug assemblies are removed.

Select the proper seal assembly tools for the 1y" inch 131.8 mm) or 1Y2 inch 138.1 mml seal diameter coupling shaft involved. See Figures 1, 2 and 3, page 2.

Insert the selected seal compression ring tool (Figure 31, with chamfered end inward, into housing (6) until it bottoms out. Assemble the selected seal thimble tool IFigure 11 over coupling shaft 1111. Coat new seal 151 with clean grease and assemble over seal thimble with lip side inward. Push new seal 151 into housing (6) with the appropriate seal driver tool (Figure 21. Remove seal driver, thimble and compression tools.

Hold washer 141 between thumb and index finger and slightly collapse washer and assemble into housing 161.

Assemble back-up washer 131 tab side out, and retaining ring 121. Be sure rounded edge of retaining ring is faced inward, and that back-up washer tab is between ends of retaining ring. Be sure the new retaining ring (2) is the same thickness as the one removed. ISeal kit contains

Place Torqmotor in a vise, clamping down on the housing 161 port bosses with the coupling shaft 1111 pointed down.

Thoroughly wash cover in proper solvent and blow dry.

Be sure the 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 cover as necessary.

NOTE: O·ring (26) is not included in seal kits but is serviced separately if required.

5.

Remove commutator ring 1211, commutator 1191, seal ring {201, and manifold (181 by using two of the special bolts (241 as a lifting tool-insert the two special bolts into two holes and lift out the previously mentioned parts.

6.

Remove seal ring 1201 from commutator (l9), using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator and commutator ring (21) for cracks or burrs. Inspect commutator for wear, scoring, spalling or brinelling. If

6

7.

8.

any of these conditions exist, replace commutator and commutator ring as a matched set.

15.

Remove housing 16) from vise, turn over and reciamll \ vise with dirt seal III end pointed up.

Remove manifold plate n7) by again using two special bolts (24) as a lifting tool. Inspect manifold 1181 and manifold plate (171 for cracks, surface scoring, brinetling or spalling. Replace manifold or manifold plate that exhibits any of these conditions. A polished pattern on the ground surfaCes from commutator or rotor rotation is normal.

16.

Remove dirt seal 111. retaining ring 12), ·back-up washer 131, washer 141, and seat (5) from housing (61. Discard seals ~ washers but ~eep retaining ring (2) for companson when selecting new retaining ring from seal kit. If burr exists on retaining ring groove, remove with a scraping tool.

Remove rotor set 116) and wear plate 1151, by again using the two bolts as a lifting tool. Retain rotor set in its assembled form, it possible, to maintain the same rotor vane to stator contact surfaces. Inspect the rotor set in its assembled form for nicks, scoring, or spalling, on any surface and broken or worn rotor splines. If any rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set.

Inspect the wear plate for cracks, brinelfing, or scoring.

17. Inspect housing 161 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.

If the housing is defective in these areas, discard the housing assembly and the disassembly of the Torqmotor is complete.

18.

If the housing assembly 161 has passed inspection to· this point, inspect the bearings 19), 1101, (12) and thrust washers (8) and 100t The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and the thrust washers must be free of brinelling and corrosion. If the housing has passed this inspection the disassembly of the Torqmotor is completed.

19.

If only the outer bearing 112) requires replacement, carefully use a suitable bearing puller to remove bearing so the housing is not damaged.

20.

If bearing 11 01 requires replacement, use a 1.488 inch 137.80mml maximum diameter shaft or a 1.745 inch 144.32 mml maximum diameter shaft based on the internal seal (5) bore diameter and press out thrust washers 181, lOA), thrust bearing 191, and bearings 1101 and (12). The housing wearplate face should be placed on a block of wood during the pressing operation to protect it. Discard thrust washers (81 and (BAI, thrust bearings 191, and bearings 110) and 1121 and replace .with new parts, as parts will have been damaged when being pressed out.

9. Place rotor set on a flat surface and center rotor 116A1 in stator t16C) such that two rotor lobes (180° apart) and a roller vane 11681 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 10 .13 mm 1of clearance, replace rotor set.

10.

11.

Remove drive link (14) from coupling shaft 1111 if it was not removed with rotor set and wear- plate. Inspect drivelink for cracks and for worn or damaged splines. No perceptible lash Iplay) should be noted between mating spline parts.

Remove thrust bearing 1131 and inspect for wear, brinelling, corrosion, and a full complement of retained rollers.

12. Remove coupling shaft 111) by pushing on the output end of shaft. 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. Replace coupling shaft if any of these conditions exist.

NOTE: Minor shaft wear in seal area is permissible.

If wear exceeds .020 inches (0.51 mm) diametrically, replace coupling shaft.

A slight "polish"· is permissible in the shaft bearing area.

Anything more would· require coupling shaft replacement.

13.

7

~)

NOTE: The depth or location of bearings (10) and (12) in relation to the housing wearplate face should be measured and noted before pressing the bearings out. This wiD facilitate the correct reassembly of new bearings.

The disassembly of Torqmotor is completed.

Remove sleeve 1221 by inserting screwdriver between sleeve and housing 161 and pry up. Inspect sleeve for deformation from the original cylindrical shape to a "barrel" or "hour glass" shape. Inspect sleeve ends for severe nicks, burrs or corrosion. Replace sleeve if any of these conditions exist.

NOTE: Minor burrs and corrision that would damage new seal rings during assembly can be removed from sleeve ends.

14.

\

Remove seal ring 171 and back up ring (7.11 if included from housing (61 and discard seal and back up ring.

(

\...

)

TORGMOTOR ASSEMBLY PROCEDURES IReference Exploded Assembly View)

/)

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. The parts should be available through most OEM parts distributors or Ross 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, sleeve, and housing and from port and sealing areas.

TORQMOTOR ASSEMBLY If the sealing diameter of the coupling shaft (11) is larger than any other diameter on the output end of the coupling shaft, begin the Torqmotor assembly procedures with Step 1 below.

If there is a diameter on the output end of the coupling shaft equal to the sealing diameter of the coupling shaft begin the procedures with Step 6 below.

1. Place housing 161 in a vise and clamp down on housing port bosses with small bore end pointed up. Apply clean grease to new seal 151 and assemble into housing with seal lip pointed inward.

2.

Hold washer (4) between thumb and index finger and slightly collapse- to facilitate assembly into housing 161.

3.

Assemble back~p washer 131 into housing (6) with the anti-rotation tab facing out.

4.

Select a new retaining ring (2) from the seal kit, that is the same thickness as the retaining ring removed.

Assemble the new retaining ring into housing 161. Be sure rounded edge of retaining ring is faced inward and that back-up washer tab is between ends of retaining ring.

HOUSING BEARING REPLACEMENT PROCEDURES 1.

) 2.

3.

)

If bearing components were removed for replacement, assemble new thrust washer lSI, new thrust bearing 191 and new thrust washer ISAI in that order into housing 161 bearing cavity. If thrust washer ISAI has a chamfer on the inside diameter, the chamfered side must face away from thrust bearing 19'.

NOTE: Thrust washer (BA) will be identical to thrust washer (8) unless a chamfered inside diameter is required because of coupling shaft design.

6.

Invert housing (6) in vise so that the large bore end is up.

7.

NOTE: An appropriate size piloted bearing mandrel is required to press in housing bearings.

Apply cellophane tape around splines or keyway on coupling shaft (111 to prevent damaging seals.

8.

lubricate and assemble coupling shaft (11 J;; firmly seating it against thrust washer ISAI. -

If bearings 1101 and 1121 required are for a 2.25 inch 157.2 mm) diameter Inominal) housing bearing bore, press in new bearing 1101 which is 1.0 inch 125.4 mm) long, into housing (6) bearing bore to a depth of 2.410 ± .010 inch 161.2 ± 0.254 mml, measured from the housing wear plate contact surface. Then, press in new bearing (12) which is .5 inch 112.7 mmllong into housing bearing bore to a depth of .115 ± .010 inch 12.92 ± 0.254 mml measured from the housing wear plate contact surface.

NOTE: Press against the lettered end of bearing cage when pressing in a roller bearing assembly.

If the bearings 1101 and (12) required are for a 2.50 inch 163.5 mm) diameter (nominal) bearing bore, press in new bearing (101 which is 1.0 inch 125.4 mmllong into housing 161 bearing bore to a depth of 2.379 ± .010 inch 160.43 ± 0.254 mml measured from housing wear plate contact surface. Press new bearing 1121 which is identical to bearing 1101 into housing bearing bore to a depth of .115 ± .010 inch 12.92 ± 0.254 mml measured from the housing wear plate contact surface.

NOTE: The bearings (10) and (12) must be assembled to the correct depths to assure the necessary clearance for thrust washer (SA) and thrust bearing (13) and to assure required bearing support.

5. Apply a small amount of clean grease to back side of new seal 111 and assemble into housing 161, if aseal11l is required.

9.

Assemble thrust bearing (13) onto end of coupling shaft

1111.

10. Assemble drive link 1141 into coupling shaft 1111 with their splines in mesh. IAlign hole in drive link with hole in coupling shaft (11), if applicable.)

NOTE: Two alignment studs screwed finger tight into housing (6) bolt holes, approximately 180-0 apart, will facilitate the assembly and alignment"pf components as required in the following procedures. The studs can be made by cutting off the heads of 3/8·24 UNF 2A bolts that are over .5 inch (12.7 mm) longer than the bolts (24) used in the Torqmotor. .

11.

Assemble wear plate 1151 over drive link (14) and studs onto housing 161. .

12. Install assembled rotor set (16) with counterbore in rotor 116AI down, if applicable, and splines in mesh with drive link splines.

NOTE: If necessary, go to "Rotor, Stator, Vane . Assembly" procedures on page 9.

13. Assemble manifold plate 1171, manifold (18) and then the commutator ring 1211 over the drive link 1141 onto rotor set 1161 per the exploded assembly view. 8e sure swirls in manifold and manifold plate are faced together.

8

4.

Assemble a new seal ring 1201, flat side up, into commutator 1191 and assemble commutat~r over end of drive link 1141 onto manifold 1181 with seal side up.

15. Assembly new back up ring 17.11 if required and new seal ring 171 on housing (61,apply a generous amount of SAE 10W40 to both ends of sleeve 122) and assemble onto housing. Make sure sleeve is sitting in a non· cocked position.

16. Turn a plug 1251 with a new O"fing (26) loosely onto each end of cover {231 valve cavity if shuttle valve {281 is required.

17. Then insert a spring {2ll, the valve {2SI and another spring 1271 into the other end of the valve cavity. Turn another plug 1251 with new O-ring {261 loosely into cover valve cavity.

If relief valve {28AI components were removed from the end cover, assemble new O-ring 1261 onto the relief valve plugs 1251. Assemble the two piece relief valve 128AI with large end of conical spring into the plug first and the small nut of the other valve piece in the small end of the conical spring. Tum these plug and relief valve assemblies into the end cover loosely to be torqued later.

18.

Assemble a new back up ring l7 .11 if required and a new seal ring !71 onto end cover and assemble end . cover onto sleeve 1221 in a non-cocked position.

21.

The assembly of Torqmotor is now complete except for woodruff key mAl, nut 11181, washer 111C), bolt (1101, lock washer 111EI or retaining ring I11FI if applicable at Torqmotor installation. See final checks. All POrts should be plugged until Torqmotor is installed in system.

f

Assemble seven special bolts (241 and screw in finger tight. Removal of the two alignment studs should be made after at least two bolts have been assembled.

Alternately and progressively tighten the bolts to pull end cover assembly (23) and sleeve 1221 into place with a final torque of 50 ± 5 ft.lbs. 168 ± 8 N mi.

Tightening sequence:

o

NOTE: The special bolt (24) required for use with the shuttle va(ve(28) end cover assembly (23) is longer than the bolt required with the standard end cover assembly. Refer to the individual service parts list for correct service part number.

20. Torque the two shuttle plug valve assemblies 1251 into a end cover assemble to 12-19 ft.lbs. 116-26 N ml. Torque the relief valve plug assemblies 1251 into an end cover assembly to 45-55 ft.lbs. 161-75 N mI.

9

\

ROTOR,. STATOR. VANE ASSEMBLY PROCEDURE A disassembled rotor 116AI, stator (l6CI and vanes (1681 that cannot be readily assembled by hand can be assembled by the following procedures.

1. Place stator naci onto wear plate (151 after following Torqmotor assembly procedures 1 through 11.

2~ If assembly alignment studs are not being utilized, align stator bolt holes with wear plate bolt holes and turn two bolts 1241 finger tight into bolt holes 180° apart to retain stator and wear plate stationary.

3.

Assemble six vanes 1l6BI into the stator vane pockets.

4.

Assemble rotor 116A), COUnterbore down, if applicable, into stator (l6C) and Onto wear plate fl5} with rotor splines in mesh with drive link splines.

5.

Grasp the outPut end of coupling shaft 111 I with locking pliers or other appropriate turning devices and rotate coupling shaft, drive link and rotor to seat the rotor and assembled vanes into stator, creating necessary clearance to assemble seventh vane. Assemble the seven vanes using minimum force. .

NOTE:. If the end cover has a valve (2S) or (28A) use the line you previously scribed on the housing (6) to radially align the end cover port into its original position.

19.

If seal 151, washer 141, back-up washer (31. snap ring I' and seal III have n~t yet been assembled, invert housin in vise so the coupling shaft 1111 is pointing up and follow procedures #3 and #4 under '"Replacement of High Pressure Seal" on page 6 to assemble these components.

6.

Remove the two assembled bolts if used to retain stator and wear plate.

-"'\.

\.J

Final Checks

Final Checks •

Pressurize the Torqmotor™ with 100 p.s.i. 16.9 BAR) dry nitrogen and submerge in solvent to check for external leaks.

•

Check TorqmotorM for rotation. Torque required to rotate coupling shaft should not be more than 50 ft.lbs. 168 N ml

•

Pressure port with "A" cast under it on housing 16) is for counter-clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with "B" cast under it is for 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:

)

•

1OW40 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: 00 not mix· oil types. Any mixture, or 'in 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 2000f 193.3OCI.

) 10

Tips for Maintaining the Torqmotor Hydraulic System

TIi

•

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 TorqmotorTM component. Replace the component with original equipment only.

•

00 not cold straighten, hot straighten, or bend any TorqmotorM part.

•

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

•

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

•

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

'.

CAUTION: 00 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 actident. 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.

Ross Gear extends close technical cooperation and assistance. If problems occur which you cannot solve, please contact our Ross Service Department or local Ross approved Distributor.

Our phone number and telex number and address are on the back cover of this manual.

l 11

Final Checks

'r.·". " ....

"-"'

<--...-:.".>

Final Checks • Pressurize the TorqmotofM with 100 p.s.i. 16.9 BAR) dry nitrogen and submerge in solvent to check for external leaks.

• Check Torqmotor'" for rotation. Torque required to rotate coupling shaft should nOl be more than 50 tt.lbs. 168 N mI • Pressure port with "A" cast under it on housing .IS} is .for counter-cIQ.ckwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with "8" cast under it is for clockwise coupling shaft rotation.

• Use test stand jf available, to check operation of the Torqmotoru .

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: 00 not DiiX oil tYPeJ•.A!1Y mixturt~.or ~n unapproved oil, could deteriorate the seals.' Maintain the proper fluid level in the tueryoir. When changing fluid, completely drain old oil from the system. It is suggested also that you flush the system with ctean oil.

Filtration Recommended filtration 20-50 micron.

Oil Temperature Maximum operating temperature 200°F 193.3°CI.

o 10

Disclaimer This Service Manual has been prepared by TRW Ross Gear Division 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. TRW Ross Gear Division 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 TRW Ross Gear MA8 & MAE TorQmotor Units. However, despite the care and effort taken in preparing this general Service Manual, TRW makes no warranties that lal 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 Ibl 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 MANUFACTURER'S SERVICE MANUAL AND WARRANTY. 00 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 TRW REPLACEMENT AND SERVICE PARTS AND THE UNIT IS RESTORED TO TRW'S SPECIFICATIONS FOR THE TORQMOTOR UNIT. It is the responsibility of the mechanic performing the maintenance, repairs or service on a particular Torqmotor unit to lal inspect the unit for abnormal wear and damage, Ibl 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 Icl 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.

)

MAB and MAE Series Service Procedure

)

Write or call for information and added details concerning your installation and applications: Phone: Telex: Write:

311.423.5371 279413 TRW Ross Gear Division 800 Heath Street lafayette, Indiana 47902

) MAB-E 109 WAJ5M 8/88

'<)

Torqmotor'" MG, MF, MB, ME Series Service Procedure

)

TRW Ross Gear Division PRICE: $3.00

Torqmotor Design Features Til

COUPLING SHAFT HIGH PRESSURE SEAL ,...tl1lJ;J;.ULJ;

THRUST BEARING

HOUSING

DIRT & WATER. SEAL, MATCHED ROTOR SET MATCHED COMMUTATOR SET

.COUPLING SHAFT HIGH PRESSURE SEAL NEEDLE THRUST BEARING DRIVE LlNK12-TOOTH SPLINES

DIRT & WATER SEAL NEEDLE RADIAL BEARING MATCHED ROTOR SET MATCHED COMMUTATOR SET

Torqmotof" MG Series features include: - The roHer vane rotor set design offers a low·friction, wear compensation which maximizes the useful performance life of the motor.

- Zero leak commutatiofl valve provides greater, more consistent volumetric efficiency.

-Design flexibility • MG affers 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 ratings 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.

- Aunique high-pressure shaft seal that eliminates the need for case drains.

- Up to 13 horse power output.

TorqmotofM MF Series features include: -Roller vanes to reduce friction and internal leakage and to maintain efficiency.

-Zero leak commutation valve provides greater, more consistent volumetric efficiency. ' -Wheel mount :tersion available.

-More starting torque thall competitive motors in applications where the shaft is side loaded. ICompetitive brands require more pressure to start the motor. I - A needle-roller mounted coupling shaft and steel-caged thrust bearing which can withstand lOOO-pound thrust loads.

-Side load capacity is 160{) Ibs 1727.3 kgJ maximum at center of output shaft.

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

-Up to 17 horsepower output.

-Greater durability due to superior lubrication and minimum drive spline wear.

- Patented 60-40 spline member arrangement transmits mllre torque with less weight.

)

Torqmotor™ Design Features

()

COUPLING SHAFT HIGH PRESSURE SEAL NEEDLE THRUST BEARING

DIRT & WATER SEAL NEEDLE RADIAL BEARING

()

MATCHED ROTOR SET MATCHED COMMUTATOR SET

COUPLING SHAFT

HIGH PRESSURE SEAL EEDLE THRUST BEARING HOUSING DRIVE L1NK14-TOOTH SPLINES

DIRT & WATER SEAL NEEDLE RADIAL BEARING MATCHED ROTOR SET MATCHED COMMUTATOR SET

TorqmotorM MB Series features include: -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 Ibs 1453.6 kg) end-thrust capacity in either direction.

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

- Up to 36 horsepower output.

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

-Superior low speed performance.

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

TorqmotofM ME Series features include: - 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 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 Ibs 1453.6 kg) end-thrust capacity in either direction.

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

-Up to 49 horsepower output.

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

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

Introduction Service Manual for Series MG, MF, MS, ME This service manual has one purpose: to guide you in maintaining, troubleshooting, and servicing the MG, MF, MB& ME Torqmotor Uow-speed, high-torque hydraulic motorI. 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.

A foldout page with the same Torqmotor exploded assembly view on both sides is provided in this manual. The component part names and item numbers assigned on this exploded assembly view correspond with names and item numbers lin parentheses} used in the disassembly and assembly procedures set forth in this manual. When this exploded assembly view page is folded out, you can easily identify components and locate their relative position on the exploded assembly view as you fonow the disassembly and assembly procedures.

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

Service parts are available through the Original Equipment Manufacturer or Ross approved MG, MF, MB & ME 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. 00 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.

l ) 4

Troubleshooting Guide NOTE: Before troubleshooting any system problem, check service 6terature

published by the equipment andlor component manufacturers. Follow their instructions, if given, for checking any component other than the TorqrnotorTIi unit.

Preparation Make your troubleshooting easier by preparing as follows:

Hydraulic Components

• work in a clean, well-lighted place;

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

• have proper tools and materials nearby; • have an adequate supply of clean petroleum-based solvent.

WARNING: SINCE SOLVENTS ARE FLAMMABLE, BE EXTREMelY CAREFUL WHEN USING ANY SOLVENT, EVEN A SMAll EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA AND OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.

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

Preliminary Checks

Visually check other components to see if they are loosely mounted, show signs of leaks, or other damage or wear.

Hydraulic systems are often trouble-free. Hence, the problem an operator complains of could be caused by something other than the hydraulic components.

I".' ) ,

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

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.

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 teaks • loss of efficiency such as speed and torque • pump loss of efficiency • pump failure • hoses become hard and brittle • hose failure A normal temperature range means an efficient hydraulic system.

Consult the manuals published by equipment and/or component manufacturers for maximum allowable temperatures 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 2000f= 193.3OCI.

5

Troubleshooting Checklist Remedy

Trouble

Cause

Oil leakage

1.

Hose fittings loose, worn or damaged

Check & replace dama~ed fittings or "0" Rings. Torque to manufacturers specifications.

2.

Oil seal rings 14) deteriorated by excess heat

Replace oil seal rings by disassembling TorqmotofM unit.

3.

Special bolt 11, lA, 18 or lCI loose or its sealing area deteriorated by corrosion

Significant loss of speed under load

\

-;

la) loosen then tighten single bolt to torque specification.

Ib) Replace bolt.

4.

Internal shaft seal 1161 worn or damaged

Replace seal. Disassem bly of TorqmotofM unit necessary.

5.

Worn coupling shaft (12) and internal seal 1161

Replace coupling shaft and seal by disassembling TorqmotcrM unit.

1.

lack of sufficient oil supply

lal Check for faulty relief "alve and adjust or replace as required.

Ibl Check for and repair worn pump. lei Check for and use correct oil for temperature of operaticn.

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

2.

High internal motor leakage

3.

Severely worn or damaged internal splines

Replace rotor set, drive link and coupling shaft by disassembling TorqmotofM 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 Torqmotof"lM unit, identify and remedy cause and repair, replacing parts as necessary.

3.

4.

lack of pumping pressure

Check for and repair w()rn pump.

Excessive binding or loading in system external to TorqmotorM unit.

locate source and eliminate cause.

CAUTION: If the hydraulic system fluid becomes overheated fin excess of 200 OF (93.3 °Cll,seals in the system can shrink, harden or crack, thus losing their sealing ability.

6

(al Replace worn rotor set by disassembling TorqmotcrM unit.

t. )

Torqmotor™ Design Features

HIGH PRESSURE SEAL NEEDLE THRUST BEARING

DIRT & WATER SEAL NEEDLE RADIAL BEARING MATCHED ROTOR SET MATCHED COMMUTATOR SET

COUPLING SHAFT

HIGH PRESSURE SEAL .-.............. THRUST BEARING

DIRT & WATER SEAL NEEDLE RADIAL BEARING MATCHED ROTOR SET MATCHED COMMUTATOR SET

Torqmotofil MB Series features include: -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 Ibs 1453.6 kg) end-thrust capacity in either direction.

- A design that is less sensitive to contaminatIon than competitive motors.

-Up to 36 horsepower output.

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

-Superior low speed performance.

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

TorqmotofM ME Series features include: - 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 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 Ibs 1453.6 kg) end-thrust capacity in either direction.

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

-Up to 49 horsepower output.

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

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

Definitions NOTE:

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

CAUTION:

A CAUTION refers to procedure that must be followed to avoid damaging the TorqmotorM or other system components.

WARNING:

A WARNING REFERS TO PROCEDURES THAT MUST BE FOLLOWED FOR THE SAFETY OF THE EOUIPMENT OPERATOR AND THE PERSON INSPECTING OR REPAIRING THE TOROMOTORTM

Disclaimer This Service Manual has been prepared by TRW Ross Gear Division for refarence and use by mechanics who have been trained to repair and service hydraulic motors and systems on commercial and non-commercial equipment applications. TRW Ross Gear Division 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 sarvicing the complete line of TRW Ross Gear MG, MF, MB & ME Torqmotor Units. However, despite the care and effort taken in preparing this general Service Manual, TRW makes no warranties that fal 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 fbi any repairs or service of a particular Torqmotor unit will result in a properly fui1ctioning Torqmotor unit.

If inspection or testing reveals evidence of abnormal wear or damage to the Torqmotor unit or if you encounter circumstances not covered in the Manual, STOP - CONSULT THE EQUIPMENT MANUFACTURER'S SERVICE MANUAL AND WARRANTY. 00 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 TRW REPLACEMENT ANO SERVICE PARTS AND THE UNIT IS RESTORED TO TRW'S SPECIFICATIONS FOR THE TOROMOTOR UNIT. It is the responsibility of the mechanic performing the maintenance, repairs or service on a particular Torqmotor unit to lal inspect the unit for abnormal wear and damage, fbi 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 Icl 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.

Patents Ross Gear Division products and systems described in this manual are protected by one or more of the following United States patents: 3,606,601. In addition, foreign patents have been issued in Canada, the United Kingdom, and West Germany.

2

<fTRW 1988

Tools and Materials Required for Servicing MG. MF, MS, ME Series Service Manual Clean, petroleum-based solvent -; Emery paper Vise with soft jaws Air pressure source Arbor press Screw driver Masking tape

CONVERSIONS INCHES .020 .021 .029 .030

.111 .119 .152 .160 .296 .304

Breaker bar Torque wrench-ft. Ibs. IN ml

.460

Sockets: 1/2 or 9116 inch thin wall, 1 inch

.470

Allen Sockets: 3/16, 3/8 inch

.500

Adjustable crescent wrench or hose fitting wrenches

.585 .595

.660

SAE 10W4O SE or SF oil Special bearing mandrel for MG.& MF Torqmotors ISEE FIGURE 11

.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

Special bearing mandrel for MB & ME Torqmotors ISEE AGURE 21 Feeler gage .005 inch 1.13 mml I

)

.

MG & MF Torqmotors require blind hole bearing pillier for 1.06 inch 126.9 mmland 1.62 inch 141.1 mml diameter bearinglbushing.

MB & ME Torqmotors require blind hole bearing puller for 1.40 inch dia. 135.6 mm) and 2.130 inch dia. 154.1 mml bearing.

Clean corrosion resistant grease. Recommended grease is ElM Lubricant #K-70M, Ross Gear Specification #045236 NOTE: The available service seal kits include the recommended grease as a grease pack #406018

IFabricate jf considered necessary) AGURE l-MG & MF

CAUTION: Mixing greases that have different bases can be detrimental to bearing life.

Torque Chart

i)·

Part Name bolt 5116 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 28

Item Number

Torque

1, lA, 18 or 1C 1, lA, 18 or lC 120 12B IMG, MFI 12B 1MB, MEl 1281MEI ,

22-26 ft. Ibs. 130-35 N ml 45-55 ft. Ibs. 160-76 N mt 140·180 ft. Ibs. 1190-244 N ml 175-255 ft. Ihs. 1237-305 N ml 300-400 ft. lbs. 1407-542 N ml 300-400 ft. Ibs. 1407-542 N mt

IFabricate if considered necessary I FIGURE 2-M8 & ME

7

\

Irqmotor™ Exploded Assembly View-Typical

/;t1::

/.'!'>...?'I-

lOA

•

~ ".

Thisc......

Included in M8 & ME - - - - - , TOflIIhOIIIrS Only.

/

12E

0-0. _

12C

_'~: J'\~~

12A

1/7)"0iL'itJ~

11 25

16 14 , //

(~./'~

14,/

/~Q61

12

/;/ '

10

NOTE: AIAmIIII Sell F1et Sift ChIt . . . . . iD ElMrIed VIew ef SecIiDIIeII Set- of hIa ,...., 5 allll 3

Item No. Description 1.

Special Bolts 15 or 71 1A. Special Bolts 1B. Special Bolts \71 1C. Special Bolts 171 2.

End Cover 3.

Seel Ring-Commutator 4.

Seel Ring (5) 5.

Commutator 6.

Commutator Ring 7.

Manifold 8.

Rotor Set SA. Rotor SB. Stator or Stator Half SC. Vane 171 BD. Stator Half BE. Vane 171 9.

Wear Plate 10.

Drive Unk

m

11.

12.

12A. 12B. 12C. 120.

12E. 12F. 13.

14.

15 16.

17.

16 lBA. 19.

Thrust Bearing Coupling Shaft

Key

Nut

Washer Bolt Lockwasber Retaining Ring Bearing/Bushing, Inner Thrust Washer Thrust Bearing Seal Backup Washer Housing a-Ring 121 Bearing/Bushing, Outer

20.

21.

22.

23.

24.

25.

Dirt & Water Seal Plug 121 O-Ring 121 Spring Valve (Shuttle or Relief) Backup Washer

) 7A

· Torqmotor™ Exploded Assembly View-Typical (Identical to page 7A)

)

C!)-l,-,=,,-18A This Cempaaent IndudId in M8 &. ME---...,

TQfqIII01II'S 0I!Iv.

...

(f~~ I l~,

)

6

II ~

4 2

/

1

Item No. Description 1.

Special Bolts (5 or 71 1A. Special Bolts 171 18.

Special Bolts 171 1C. Special Bolts 2.

End Cover 3.

Seal Ring-Commutator 4.

Seal Ring 151 5.

Commutator 6.

Commutator Ring 7.

Manifold B. Rotor Set 8A. Rotor BB. Stator or Stator Half BC. Vanem BO. Stator Half BE. Vanej7) 9.

Wear Plata 1O. Drive Link

m

) 78

11.

12.

12A. 128.

12e.

120.

12E. 12F. 13.

14.

15 18.

17.

18 IBA. 19.

Thrust Bearing Coupling Shaft

Key

Nut Washer· Bolt Lockwasher Retaining Ring

Bearing/Bushing. Inner Thrust Washer Thrust Bearing Seal Backup Washer Housing O-Ring (2) Bearing/Bushing. Outer

21.

Dirt & Water Seal Plug (21

22.

23.

24.

25.

Spring Valve IShuttle or Relief, Backup Washer

20.

O-Ring 121

MG Service Parts List Chart CHART USE EXAMPLE: MG020601AAAB TORQMOTORfM INCLUOES PART NUMBERS LISTED TO THE RIGHT OF MG(SERIESI. 02lDISP.). 06(HOUSINtil. 01(SHAFTI. AND AAAB (OPTION) SHOWN IN LEFT HAND COLUMN OF CHART. CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TDRaMOTORS LISTED ONLY. REFER TO THE ORIGINAL EQUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TDRaMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BELOW. EXPLODED VIEW ITEM # DESCRIPTION Service Part #

5&6 COMMUTATOR & RING ASSY MF018000·A1

EXPLODED VIEW ITEM #

7

9

a'3

MANIFOLD MFOl5000

WEAR PlATE 477341'

BRONZE BUSHING 069511

8 ROTOR SET

14 THRUST WASHER 028483

15 THRUST BEARING 065066

17 BACKUP WASHER 028516

"OU" BEARING 065505

,//"\ )

20 IlIRT & WATER SEAL 478036

10 ORIVE LINK

DESCRIPTION BOLT (5) 02· Service Part # 021311 MF027003 MF023000 03Service Part # 021311 MF037003 MF033000 04Service Part # 021306 MF047003 MF043000 05Service Part # 021382 MF051003 MF053000 06Service Part # 021357 MF067003 MF063000 ~ 08Service Part # 021307 MF087003 MFOB3000 Q 13 10· Service Part # 021358 MF107003 MF103000 !Z 12Service Part # 021308 MF121003 MF123000 2 14· Service Part # 021359 MF147003 MFl43000 ~ 16· Service Part # 021310 MF167003 Mf163000 ~ 18Service Part # 021383 MF187003 MF183000 a.. ~20~·__~Se~rv_ic~e_Pa~rt~#____~02~13~84~~M~FW~7~OO~3~~M~n~03~O~OO~

S

EXPLODED VIEW ITEM # HOUSING DESCRIPTION SERVICE PART # O·RING (2) 06· Service Part # MF012001·A2 ~ 09Service Part # MF012003·A2 Q 13 10· Service Part # MF012004-J2 03220!J.l0 ~ 11· Service Part # MF012005·J2 0322O!J.10 en 12Service Part # MF012006-A2 S 13· Service Part # MF012007-A2 :~--~~~~------~~~~------------EXPLODED VIEW ITEM # 12 12A 12B COUPLING WOODRUFF DESCRIPTION SHAFT KEY NUT ~ 01· Service Part # MF01S007 ~ 09· Service Part # MFOl SOOO ~ 10· Service Part # MF01S006 G124553 !;i 11Service Part # MF019003 ~ 12Service Part # MF019004 G124553 025136 ~ 13· Service Part # MF01S005 G124553 ~ 14· Service Part # MF019001 S 15· Service Part # MF019002

)

~ ----------------~~~--------------EXPLODED VIEW ITEM #

a..

S ex:

DESCRIPTION Service Part # Service Part # Service Part #

2 END COVER MG016000 MG016000 MG016000

3 COMMUTATOR SEAL 032435 032435 032435

4 SEAL RING (5) 032821 032821 032822

16 INNER SEAL 032377 032377 03280S

CoO

AAAB

ii: Q

~~~~~~----~~~--~~=---~~=-~==~

~ MAC

MAH

aService housing ass'y ITEM #18 with part number suffix-A2 includes ITEM#13 and #lS. Service housing ass'y ITEM 118 with part number suffix-J2 includes ITEM #13, 119 AND two ITEM leA. Standard seal kit SK000090 includes five #032821 seal rings, #032435 commutator seel,/032377 inner seal,/028516 back up washer. 1478036 dirt 8:1 water seal, 1406018 grease pack, bulletin # 887.

Special seal kit SKOOO091 for units that use fire retardant fluids include five #032822 seal rings, 1032435 commutator seal, #032809 inner seal, 1028516 baCK up washer, 1478036 dirt & water seal, #406018 grease pack, bulletin #887.

8

)

MF Service Parts List Chart CHART USE EXAMPlE: MF020601AAAA TOROMOTOR'M INCLUDES PART NUMBERS LISTED TO THE RIGHT OF MF(SERIESI. 02lOlSP.I. O&(HOUSINGI. 01(SHAFT) AND AAAA (OPTIONI SHOWN IN lEFT HAND COLUMN OF CHART. " (

)

CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TOROMOTORS LISTED ONLY. REFER TO THE ORIGINAL EQUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TOROMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BELOW. EXPlODED VIEW ITEM # DESCRIPTION Service Part I EXPLODED VIEW mM# DESCRIPTION Service Part # Service Part # Service Part # Service Part # Service Part # Service Part # Service Part # Service Part # Service Part # Service Part # Service Part # Service Part #

020304-

05· 06!is 08· ~ 10~ t 2z ~ 14· ~ 16:s 18~ 20Q

7

5&&

COMMUTATOR & RING ASSY MF018000-A 1

BOLT (5) 021311 021311 021306 021382 021357 021307 021358 021308 021359 021310 021383 021384

9 WEAR

MANIFOLD MF015000

PlATE 417341

8 ROTOR

ro DRIVE

SET MF027003 MF037003 MF047003 Mf057003 MFD67003 MF087003 MF107003 MF127003 MF147003 Mf167003 MF187003 MF207003

UNK MF023000 MF033000 Mf043000 MF053000 MF063OIJO MF083000 Mfl03000 MFl23000 MFl43000 MF163000 MFl83000 MF203000

NEEDLE BEARING 059512

14 THRUST WASHER 028483

15· THRUST BEARING 065066

17 BACKUP WASHER 028516

NEEDLE BEARING 065506

20 DIRT & WATER SEAL 478036

~--------~------------~~--~~--EXPLODED VIEW ITEM #

HOUSING DESCRIPTION SERVICE PART I O·RING (21 Q,. 06Service. Part # MF01200l-A1 09Service Part # MF012003-Al 032200-10 ~ 10Service Part # MF012004-Jl 032200-10 ~ 11Service Part # MF012005-J1 c;; 12Service Part # MF012006-Al ~ ~13~-__~S_erv~ice~Pa~rt~#______~M~FO~1~2O~0~7.~A1~____________

a

EXPLODED VIEW ITEM # DESCRIPTION Service Part # Service Part # Service Part # Service Part # Service Part # Service Part # Service Part # Service Part #

!is 01· ~

0910· ~ 11CIl 12· ~ 13i 1415~

a

12 COUPlING SHAFT MF01S007 MF01SOOO MFOl9006 MF019003 MF019004 MF019005 MF019001 MFOl9002

12A WOODRUfF KEY

129 NUT

G124553 G124553 G124553

025136

y~--~~~~----~~~---------------

EXPLODED VIEW ITEM #

!is AAAA AAAC ~ AAAD ii: AAAG

Q

~

)

DESCRIPTION Service Part # Service Part # Service Part # Service Part #

2

3

4

END COVER MFOl6000 MF016000 MF016000 MF016000

COMMUTATOR SEAL 032435 032435 032435 032435

SEAL RING (51 032821 032821 032821 032822

16 INNER SEAL 032377 032377 032809 032809

Q--~~~~~----~~~--~~~--~;;=-~~~

aService housing ass'y ITEM #18 with part number suffix-Al includes ITEM #13 and #19. Service housing ass'y ITEM #18 with part number suffix-Jl includes ITEM #13, #19 AND two ITEM 18A. Standard seal kit SK000090 includes five #032821 seal rings. #032435 commutator seal, #032377 inner seal, #028516 back up washer, #478036 dirt & water seal, #406018 grease pack, bulletin #887.

Special seal kit SKOG0091 for units that use fire retardant fluids include five #032822 seal rings, 1032435 commutator seal,#032809 inner seal,#028516 back up washer, #478036 dirt & water seal, 1406018 grease pack, bulletin #887.

9

MB Service Parts List Chart CHART USE EXAMPLE: MB050101AAAA TOROMOTORTM INClUDES PART NUMBERS LISTED TO THE RIGHT OF MBCSERlES). OSlDISP.). 01(HDU:)INGI. 01(SHAFT) AND AAAA (OPTION) SHOWN IN LEFT HAND COLUMN OF CHART, CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TOROMOTORS LISTED ONLY. REFER TO THE ORIGINAL EQUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TORQMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BElOW. EXPLODED VIEW ITEM # COMMUTATOR WEAR THRUST INNER THRUST THRUST BACKUP OUTER OIRT 8 WATER BACKUP ~ DESCRIPTION ASSEMBLY MANIFOLD PLATE BEARING BEARING WASHER (2) BEARING WASHER BEARING SEAL WASHER

~ ~MB~-__~Se~N~ice~P~ar~t#~__~M~EO~1~80~OO~-A~1~M~B~01~~~0~0~4~7~73~~~0~6~OO~24~~0~71~0~19~~40~Ol~3~6__~06~OO~1~7~m:~~15~~0~68~02~7____4~7~80~35~__~02~9~11~8 EXPLODED VIEW ITEM # DESCRIPTION

b(SELECT ITEM # BOLT PER OPTION GROUP) OR lA OR lB OR 1C BOLT (7) BOLT (7) BOLT (7) BOLT (7)

1

8 ROTOR SET

10 DRIVE LINK

05· 06~ 08~ 09!Z 10· ~ 12~ 15~ 18· ~

SeNice Part # 021326 021340 021386 MB057003 MB063000 Service Part # 021326 021340 021386 MB067003 MB063000 Service Part # 021271 021386 021273 021273 MB087003 MB083000 Service Part # 021390 021273 021273 021379 MB097003 MB093000 Service Part # 021376 021387 021387 021391 MB107003 MBlO3000 Service Part # 021352 021379 021379 MB127003 MB123000 SeNicePart# 021272 021391 MB157003 MB13~ SeNice Part # 021340 021392 021392 021385 MB187003 MBl83000 ~23~·___S~er~~c~e~Pa~rt~#____~0~2~13~87~__~O~21.3~78~__~0~21~3~78~________~M~B~23~7~OO~3__~M~B2~~~~ EXPLODED VIEW ITEM # DESCRIPTION

a..

a ffi

~ ~ ~

0102040506-

SeMce SeNice SeNice Service SeMce

Part # ME012001-Al Part # ME012002-A 1 Part # ME012004-A1 Part # ME012005-Al Part # ME012006-Al ~07~-__~S~erv_i_ce_P_art~#______ M~EO~I~20~0~7~~1~_ EXPLODED VIEW ITEM #

~

01-

ail 02;: 03~ 04~ 05· ~ 06~ 07· 08·

a

u

a18 SERVICE HOUSING ASS'Y

12

12A

12B

"12C

120 5/8·18

DESCRIPTION

COUPLING SHAFT

KEY

NUT

WASHER

SeNice Service SeNice Service Service SeNice SeNice SeNice

MB019001 MB019002 MB019003 MB019004 MB019005 MB019006 MB019007 MB019000

Part # Part # Part # Part # Part # Part # Part # Part #

G124553 039028

G124554

12F RETAINING RING

028413

G223734

Gl03325

~1333

028413

G223734

G103325

l )

c025126

EXPLODED VIEW --------------------~--~-----------------------------------ITEM # bl,lA,IB,IC 121 & 22 16

d.f22

COMMUTATOR SEAL INNER PLUG & Q·RING RING (5) SEAL SEAL ASSEMBLY

O·RING

SPRING (21

\lAlVE

032200-90 032200-90 032424 032424 032424 032424

401642 401642

41 5569 415569 410009-74 410009-71 410009-72 41 0009-73

2

AAAA AAAC AAAF AAAG AAAH MAM AAAN MAP MAT ~ AAAU ~ BBBA ~ BBBB ~ BBBC g;; BB80

10

BOLT

12E LOCK WASHER

DESCRIPTION

BOLT (7)

SeNice Service Service Service SeNics SeNice SeNice SeNice SeNice SeNice Service Service Service SeNice

item item Item Item item item Item Item Item Item item Item Item Item

Part # Part # Part # Part # Part # Part # Part # Part # Part # Part # Part # Part # Part # Part #

#1 #1 #1 #1 #1 #1B #1B #1B #lA #IA #IC #1C #1C #1C

ENO COVER

MB016000 MB016000 MB016000 MBOI6000 MB016000 ME016002 ME016002 eME016001·Jl fME016003-Al fME016003-A 1 fME016004-A 1 fME016004-A2 fME016004.A3 fME016004-A4

3

032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435 032435

4

032819 032819 032819 032820 032820 032819 032819 032819 032819 032819 032819 032819 032819 032819

032817 032817 032817 032818 032818 032817 032817 032817 032817 032817 032817 032817 032817 032817

415463-A2 415463-A2 411063-A1 411063-Al 411063-A1 411063·A1

121, 1000PSI 121, 2000PSI 121, 3000PSI 121 , 4000PSI

aService housing ass'y ITEM 118 with part number suffix·A1 includes ITEM 113,#14 two reQ'd, 115 and 119. bSelect the required bolt number in designated "DISPLACEMENT GROUP" under bolt ITEM 11,lA.1B or 1C shown in designated "OPTION GROUP." CNut #025113 is required if the designated "OPTION GROUP" is AAAF, AAAN, or AAAU. 1·20 UNEF dlTEM #22 is part of plug & Q·ring assy's but can be serviced separately. ~Service and cover ME016001·J1 includes lWo/032200-10 a·rings, ITEM 18A an1he exploded ass'y view that can also be serviced separately.

End cover assembly item #2 also includes item #21, #22. #24 and if required item #23. All but item #21 can be serviced separately. gME018001·A1 commutator ass·y. is required if the designated "OPTION GROUP" is AAAM, AAAN, or AAAP. Standard seal kit SK000092 includes five 1032819 seal rings, #032435 commutator seal, #032817 inner seal, #028515 and #029118 back washers. # 478035 dirt & ,'. ater seal, #406018 grease pack, bulletin #687.

Special seal kit SKOOO093 for units that use fire retardent flUids includes five 1032820 seal ringS,/032435 commutator seal, 1032818 inner seal,#028515 and ;1)29118 bas, :;p washers, #478C35 dirt & water seal. #406018 grease pack, bulletin #687.

ME Service Parts List Chart

()

CHART USE EXAMPlE: MED9D1D1AAAA TORQMOTORTM INCLUDES PART NUMBERS USTm TO THE RIGHT OF MECSERIESI. 09(OISP.I. 01(HOUSJNGI. 01(SHAFTI ANO AAAA (OPTIONI SHOWN IN LEFT HAND COLUMN OF CHART. CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TOROMOTORS USTEO ONLY. REFER TO THE ORIGINAL EQUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TORQMOTOR FOR ASSEMBLY NUMBERS NOT USTED BELOW. EXPlODED VIEW ITEM # COMMUTATOR WEAR THRUST INNER THRUST THRUST BACKUP OUTER DIRT & WATER BACKUP ~ DESCRIPTION ASSEMBlY MANIFOLD PlATE BEARING BEARING WASHER (2) BEARING WASHER BEARING SEAL WASHER

~ME~.__~Se~N~=·e~P~an~/~__~ME~0~18~00~0.~A1~M~E~D1~5~000~4~7~7~~2~0~6=~~24~~0~71~01~9__~400~13~6__~0=OO~01~7~0=2~~15~~0~==2~7__~47~8=ro~5__~02~9~"~8

;

blSELECT ITEM # BOLT PER OPTION GROUPI 1 OR 1A OR lB OR lC 8 10 BOLT In BOlT In BOLT In BOLT 171 ROTOR SET DRIVE LINK 09· Service Partl 021390 021273 021273 021379 ME097003 MED93000 12SeNiee Partl 021352 021319 021379 ME127003 MEl23000 15Service Partl 021272 021391 ME1570ro MEl53000 18.

Service Part # 021~ 021393 021392 021385 ME187003 MEl83000 21.

Serviee Part # 021273 021385 021385 ME217003 ME213000 29Service Part# 021392 021394 021394 021393 ME291003 ME293IlOO 3483,.

Service Pan # 021385 021393 021393 021395· ME337003 ME333000 Serviee Part# 021395 021388 021388 ME487003 ME483000 ~58~·__~Se~rv~ice~Pa~r~t#~__~0~21~300~____0~2~13~~~__~02~13~8~9__________~M~E5~87~00~3__~M~~~83000~__ EXPLODED VIEW ITEM # a'8 SERVICE DESCRIPTION HOUSING ASS'Y 01SeNiee Part # ME012001·A1 02Service Part # ME012002-A1 04· SeNiee Part I ME012004-Al 05SeNiea Part # MEO 12005-A1 06Service Part # ME012006-Al ~07~·__~S~erv~ie~e_P~ar~t/~__~M~E~01~20~0~7-~A1~_ EXPLODED VIEW 12B ITEM # 12 12A 120 12E 12F 12C COUPUNG RETAINING 5/8·18 LOCK KEY NUT WASHER RING DESCRIPTION SHAFT BOLT' WASHER 01Service Part # ME019001 02Service Part # MEOl9002 6124553 028413 G223734 Gl03325 03Service Part # ME019003 039028 401333 04Service Part I ME019004 05Service Part # ME019005 02B413 6223134 G103325 06· Service Part # MEOl9006 07Service Part # ME019001 08SeNice Part I MEOl9000 6124554 c025126 17Service Part # ME019008 18Service Part # ME019009 19· SeNice Part # ME019010 G124554 !lQ2513B ~W~·__~S~erv~ic~e~Pa~rt~#~__~M~EO~19~01~1__=03~90~2B~______~0~2~85~lB~~6~22~37~3~4~G~1033~25~~~~1~~~B__ EXPLODED VIEW d,f22 f21 & 22 16 3 4 ITEM # b',lA,'B,IC 2 END COMMUTATOR SEAL INNER PLUG & O·RING DESCRIPTION BOLT (7) RING (5) SEAL ASSEMBLY (2) O·RING SPRING (21 COVER SEAL AAAA Service Part # Item #1 ME016000 032435 032819 032817 AAAC Service Part # Item #1 ME016000 032435 032819 032817 AAAF Service Part # ME016000 Item #1 032435 032819 ro2817 Item #1 ME016000 AAAG Service Part # 032435 032820 032818 ME016002 AAAM Service Part # hem #1 B 032435 032819 032817 AAAN Service Part # Item #1 B ME016002 032435 032819 032817 eME016001·J1 AAAP Service Part # Item #1 B 032435 032819 032817 AAAT Service Part # Item #1 A 415463-A2 032200-90 401642 032435 032819 032817 ffME016003.A 1 AAAU Service Part # Item #1 A 032435 . . 032819 032817 415463·A2 032200-90 401642 fME01600J.A 1 ME016004-A 1 BBBA Service Part # Item #1 C 032435 032819 032817 411063-A1 032424 BBBB Service Part # . 032819 032817 Item #lC ffMEOl6004.A2 032435 411063-Al .032424 Item #1 C ME016004-A3 032435 032B19 032817 41106J.Al 032424 BBBC Service Part # fME016004-A4 Item #1 C 032435 032819 032817 411063-A1 032424 B880 Service Part # EXPLODED VIEW ITEM # DESCRIPTION

~

_

c::I

!Z

i

~~a

e:

~

i

~

z:

~

~

t) Q,.

a

m t: ~

c::I

3!: ~

8

ga: c::I

~ ~

.J

VALVE

415569 415569 410009-74121,1000PSI 410009·71 121, 2000PSI 410009-72 121, 3000PSI 410009-73 121. 4000PSI

aService housing ass'y ITEM #18 with part number suffix·Al includes ITEM #13,/14 two req'd,/15 and /19. bSelect the ~eQuired bolt number in designated "DISPLACEMENT GROUP" under bolt ITEM #l,lA,IB or lC shown in designated "0PT10N GROUP." ~1'20 UNEFnut #025113 is required if the ~signated "OPTION GROUP" is AAAF, AAAN, or AAAU .

ITEM #22 IS part of plug & o·ring assy's but can be serviced separately. ~Service end cover MEOl6001·Jl includes twO #032200-10 o·rings,ITEM 18A on the exploded ass'y view that can also be serviced separately.

End cover assembly Item #2 also Includes Jlem#21, /22,#24 and If reqUired Jlem #23. All but·ltem #21 can be serviced separately. ~11/8.1B UNEF nut #025139 is required il the designated "OPTION GROUP" is AAAf, AAAN, or AAAU ME018001-Al commutator ass'y. is required if the designated "OPTION GROUP" is AAAM, AAAN, or AMP. Standard seal kit SK000092 includes live #032819 seal rings, #032435 commutator seal, #032817 inner seal, # 028515 and #029118 back wash:'!, 1478035 dill & water seal, # 406018 grease paCk, bulletin #687.

Special seal kil'SK000093 for units that use fire retardent fluids includes five #032820 seal rings, #032435 commutator seal, #032818 inner seaI,#02E:'5 and #0291 is oack up washers, #478035 dirt & water seal, #406018 grease pack, bulletin #687.

11

ME Service Parts List Chart usc

r

(,

CHART EXAMPLE: ME090101AAAA TOROMOTORTM INClUDES PART NUMBERS LISTED TO THE RIGHT OF MEISCRIES), 09l0lSP.). 01lHOUSJNGI, 01lSHAFTI AND AAAA (OPTION) SHOWN IN LEFT HAND COWMN OF CHART. CAUTION: THE CHARTED COMPONENT SERVICE INFORMATION IS FOR THE TOROMOTORS lISTED ONlY. RefER TO THE ORIGINAL EQUIPMENT MANUFACTURER OF THE EQUIPMENT USING THE TORQMOTOR FOR ASSEMBLY NUMBERS NOT LISTED BelOW. EXPlOOEO VIEW a,§ a,~ 17 h5 &6 1 11 a'9 25 ITEM # a'4 ~ WEAR THRUST INNER THRUST THRUST BACKUP OUTER DIRT & WATER BACKUP COMMUTATOR en WASHER DgSCRIPTIQN ASSgMBlY MANIFOLD e!:ATE BEARING BEARINg WASHER 121 BEARING WASHER BEARING SEAb !!:! a: 068027 478035 028515 029118 ME015000 477342 068024 400136 069017 071019 Service Part # ME018000·Al ME· ~ b(SElECT ITEM # BOLT PER OPTION GROUP) .

EXPlOOED VIEW OR 10 1A OR 1B 8 1C 1 OR ITgMt DESCRIPTION BOLT !11 BOLT IZl BOLT III ROTOR SET DRIVE LINK gTlll ME093000 021273 021273 021379 ME097003 Service Part # 021390 09· 0..

MEl23000 021379 ME127003 021379 Service Part # 021352 12S ME15300D 021391 ME157003 Service Part # G21272 cz: 15<.::I MEl80000 021385 ME187003 021392 021393 021340 ....z 18- Service Part # ME21:D1O 021385 ME217003 021385 021273 Service Part # 21i.... 29- Service Part # 021394 021394 021393 ME297003 ME293000 021392 021395 . ME337003 ME333000 021393 021385 021393 Service Part # 33:l ..... 48ME483000 021388 ME487003 021388 021395 Service Part # ~ 021389 ME583000 021389 Service Part # 021396 ME5870Q3 58Q EXPLODED VIEW a'8 ITEM # SERVICE HOU§ING ASS'Y DESCRIPTION ME012001-A1 Service Part # ~ 01ME012002-Al i 02- Service Part # ME012004·Al Service Part # ~ 04· MEOl2005-Al Service Part # z 05· .~ 06· MEOl2006-Al Service Part # Service Part # MEQ12007-A1 ~ 07EXPLODED VIEW 12A 12B 12 12C 12D 12E 12F ITEM # COUPLING RETAINING 5/8·18 LOCK BOLT . WASHER NUT SHAFT KEY WASHER RING DESCRIPTION 01ME019001 Service Part # Service Part # MEOI9002 G124553 0203Service Part # 039028 028413 G223734 Gl03325 ME019003 401333 Q.. 04Service Part # ME019004 028413 6223734 6103325 S 05- Service Part # MEOl9005 Service Part # ME019006 ~ 06ti: 07Service Part # ME019007 Service Part # ~ 08MEOl9000 6124554 c025126 Service Part # MEOl9008 ~ 171:! 18Service Part # ME019009 Service Part # ME019010 G124554 9025138 ~ 19MEOl9011 039028 028518 G223734 6103325 401658 8 20. Service Part # EXPLOOEO VIEW d"22 ITEM # b1, lA, lB,lC 16 4 2 3 '21 & 22 '23 '24 END COMMUTATOR SEAL INNER PlUG & D·RING DESCRIPTION SEAL RING 151 SEAL ASSEMBLY (~ O·RING SPRING 121 VALVE BOLT !11 COVf6 AAAA Service Part # Item #1 ME016000 032435 032819 032817 AAAC Service Part # Item #1 ME016000 032435 032819 032817 AAAF Service Part # item #1 ME016000 032435 032819 0328T7 AAAG Service Part # item #1 ME016000 032435 032820 032818 AAAM Service Pan # Item #lB 032435 ME016002 032819 032817 AAAN Service Part # item #IB 032435 ME016002 032819 032817 eMEOI6001-Jl AAAP Service Part # item #18 032435 032819 032817 AAAT Service Part # item #lA 032819 032817 401642 415569 032435 415463-A2 032200-90 :MEOI6003:A1 Q.. ;::) 032435 . • 032819 032817 AAAU Service Part # item #lA MEOI6003-A 1 401642 415569 415463-A2 032200·90 i<.::I BBBA Service Part # Item #IC 032435 .032819 032817 410009-74121, 1000PSI :MEOI6004.A 1 032424 411063-A1 . 032819 032817 Ilem #IC 032435 410009·71 121, 2000P$1 032424 fMEOl6004.A2 411063·A1 zQ BBBB Service Part # Item #le MEOl6004-A3 032819 032817 032435 032424 410009-72121.3000PSI 411063-Al j:; BBBC Service Part # Q.. fME016004-A4 BBBD Service Part # Item #le 032435 032819 032817 410009-73 121, 4000PSI 032424 411063·A1 Q

a

aService housing ass'y ITEM #18 with pan number suffix·A1 inctudes ITEM #13, # 14 two reQ'd, #15 and #19. bSelect the required bolt number in designated "DISPlACEMENT GROUP" under bolt ITEM #l,lA,lS 111 1C shown in designated "OPTION GROUP: c'·20 UNEF nut #025113 is required if the designated "OPTION GROUP" is AAAf, AAAN, or AAAU. dlTEM #22 is part of plug & o·ring assy's but can be serviced separately. eService end cover ME015OO1·J1 includes two #032200·10 o·rings, ITEM lSA on the exploded ass'y view that can also be servICed separately. fEnd cover assembly item #2 also includes item #21. #22, #24 and if required item #23. Ail but item #21 can be serviced separately.

9,1/8·18 UNEF nut #025139 is required if the designated "OPTION GROUP" is AAAF, AAAN, or AAAU hME018oo1.Al commutator ass'y, is required ilthe designated "OPTION GROUP" is AAAM, AAAN, or AAAP. Standard seal kit SK000092 includes five #032819 seal rings, #032435 commutator seal.#032817 inner seal,#028515 and #029118 back wash:'s, #478035 dlf! & water seal,#406018 grease pack, bulletin #687, Spee,al seal kirSKOOO093 for units that use fire retardant fluids includes five #032820 seal rings, #032435 commutator seal, #lJ32S18 inner seal,#026:.'o and #0291iS back up washers, #47803: dirt & water seal,#406018 grease pack, bulletin #687.

11

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 MG or MF or the large Frame Series MB or ME 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 cover construction from the alternate views shown on page 7A and 7B. • The Small Frame Series MG & MF Torqmotors will have a 3.66 inch 192.9 mm) main body outside diameter and five 5/16-24 UNF 2A cover bolts. The large Frame Series MB &ME Torqmotors will have a 5 inch 1127.0 mm) main body outside diameter and seven 3/8 24 UNF 2A cover bolts.

• Refer to page 7 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 shah.

• Remove coupling shah 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.

IA piece of wrapping paper makes an excellent disposable top,) • 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: SINCE THEY 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 hydra. 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 Ross or OEM approved service parts.

12

Disassembly and Inspection (Reference Exploded Assembly View)

(J

place Torqmotor

1.

in a vise

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

WARNING

scribe alignment mark & loosen valve plugs

Place the Torqmotor in a soft jawed vice, with coupling shaft 1121 pointed down and the vise jaws clamping firmly on the sides of the housing 118) mounting flange or port bosses. Remove manifold port O-Rings 110A) if applicable.

2.

. Figure 3

Scribe an alignment mark down and across the Torqmotor components from end cover (2) to

housing 1181 to facilitate reassemblv orientation where required. Loosen two shuttle or relief valve plugs 1211 for disassembly later if included in end cover. 3116 or 3/8 inch allen wrench or 1 inch hex socket required. SEe FIGURE 3 & 4.

Figure 4

c.

)

Figure 5

)

remove special bolts & inspect bolts

3.

Remove the five or seven special ring head bolts

t1, 1A, 18, or 1CI 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

13

wash & inspect end cover

6.

NOTE

remove & inspect commutator ring 14

Thoroughly wash end cover 121 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: A polished pattern Inot scratches) on the cover from rotation of the commutator 15) 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 161. SEE FIGURE 10.

Inspect commutator ring for cracks, Of burrs.

Figure 10

remove & inspect commutator

8.

Remove commutator 151 and seal ring 131.

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 Of 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 171 and inspect for cracks surface scoring, brinelling Of spalling. Replace manifold if any of these conditions exist. SEE FIGURE 13. A polished panern on the ground surfaces from commutator or rotor rotation is normal. Remove and discard the seal rings 141 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 servjce.

Compare configuration of both sides of the manifold to ensure that same surface is reassembled against the rotor set.

10.

Remove rotor set 181 and wearplate 191 together to retain the rotor set in its assembled form" maintaining the same rotor vane IBC) to stator 1881 contact surfaces. SEE FIGURE 14. The drive link 1101 may come away from the coupling shaft 112) 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 IBAI and wearplate. SEE FIGURE 15, Page 16. 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 141 that is between the rotor set and wearplate.

Figure 13

NOTE: The rotor set (S, 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.

Figure 14

Figure 12

15

NOTE

NOTE: Series ME Torqmotors may have a rotor set with two stator halfs (8B & 80) with a seal ring (41 between them and two sets of seven vanes (8C & 8EI. Discard seat ring only if stator halts become disassembled during the service procedures.

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

NOTE

check rotor, vane clearance

11.

NOTE

remove & inspect drive link

remove thrust bearing

13.

Figure 15

Place rotor set lSI and wear plate 191 on a flat surface and center rotor IBAI in stator IBBI such that two rotor lobes 11 BO degrees apartI and a roller vane IBCI centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gage at this comm{)n centerline. If there is more than .005 inches 10.13 mml of clearance, replace rotor set.

SEE FIGURE 16.

NOTE: If rotor set (8) has two stator halfs (8B & 80) and two sets of seven vanes (BC & 8E) as shown in the alternate construction ME rotor set assembly view, check the rotor lobe to roller vane clearance at both ends of rotor.

12.

,/)

Remove drive link 110l from coupling shaft 1121 if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash Iplay) should be noted between mating spline parts.

SEE FIGURE 17. Remove and discard seal ring 141 from housing 11 BI.

.Figure 16

Figure 17

Remove thrust bearing 1111 from top of coupling shaft 1121 if Torqmotor is a Series MB or ME. Inspect for wear, brinelling, corrosion and a full complement of retained rollers. SEE FIGURE 1B. Figure 1B

16

check coupling shaft for rust or corrosion

14.

I) \

Check exposed portion of coupling shaft 1121 to be sure you have removed aU 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 112A), nut 11281, washer 02CI, bolt 11201, lock washer 02EI, or retaining ring f12FI. Figure 19

remove &inspect coupling shaft

15.

NOTE

t)

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

Figure 20

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

NOTE

remove seal ring from housing

Remove coupling shaft 1121, 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.

16.

Remove and discard seal ring 141 from housing

1181.

Figure 21

remove & inspect thrust washer & thrust bearing

)

NOTE

17.

Remove thrust bearing 115) and thrust washer 1141 if the unit is a Series MG or MF. Inspect for wear, brineHing, corrosion and a full complement of retained rollers. SEE FIGURE 22.

NOTE: Large Frame Series MB & ME Torqmotors have a thrust bearing (15) sandwiched between two thrust washers (14) that caMot be removed from housing (18) unless bearing (13) is removed for replacement.

Figure 22 17

remove seal & washer or washers

18.

Remove seal 1161 and back up washer 1171 from Small Frame, MG & MF housing 1181. Oiscard .both. SEE FIGURE 23.

")

Remove seal 1161, backup washer 1171, and backup washer 125) from Large Frame, Series MB & ME Torqmotor housing by working them around unseated thrust washers 1141 and thrust bearing 115) and out of the housing. Discard seal and washers. SEE FIGURE 24.

NOTE

NOTE: The original design units of large Frame, Series MB & ME Torqmotors old not include backup washer (25), but must include backup washer (25) when reassembled for service.

Figure 23

figure 24

remove seal

19.

Remove housing 1181 from Vise, invert it and remove and discard seal 1201. A blind hole bearing or seal puller required. SEE FIGURE 25.

Figure 25

inspect housing assembly

20.

Inspect housing 1181 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.

c) Figure 26

18

inspect housing bearing/bushing

21.

If the housing 1181 assembly has passed inspection to this point, inspect the housing bearingsJbushings 1191 and (131 and if they are captured in the housing cavity the two thrust washers 1141 and thrust bearing 1151. 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 brinelfing and corrosion. SEE FIGURE 27. The MG Series bushing 1191 or 1131 to coupling shaft diametral clearance must not exceed .010 inch 1.025 mml. A bearing, bushing, or thrust washer that does oot pass inspection must be replaced. SEE AGUAE 28. If the housing has passed this inspection the disassembly of the TorQmotor is completed.

Figure 27

Figure 28

NOTE

NOTE: The depth or location of bearing/bushing (13) in relation to the housing wear plate surface and the depth or location of bearinglbushing (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 bearingslbushings.

Figure 29

SEE FIGURE 29. remove bearings or bushings & thrust washers

22.

If the bearings, bushing or thrust washers must be rep/acad use a suitable size bearing puller to remove beariogJbushings 1191 and 1131 from housing (181 without damaging the housing.

Remove thrust washers 1141 and thrust bearing 1151 if they were previously retained in the housing by bearing 1131. SEE FIGURES 30 & 31.

THE DISASSEMBLY OF TOROMOTOR IS COMPLETED.

Figure 30

Figure 31

19

Torqmotor™ Assembly • Replace all seals and seal rings with new ones each time you reassemble the Torqmolor 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 Ross approved TorqrnotorM 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 COMPtY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.

press in outer bearing/bushing

1.

If the housing 11 BI bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing 1191 with clean corrosion resistant grease recommended in the material section on page 7. Press the new bearinglbushing 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 on page 7 which will control the bearing/bushing depth.

Small Frame Series MG and MF TorQmotor housings require the use of bearing mandrel shown in figure 1 on page 7 to press bearinglbushing (19) into the housing to a required depth of .151/.161 inches 13.B4/4.09 mm) from the end of the bearing counterbore.

SEE FIGURE 33.

Figure 32 MS, ME seal kit

Figure 33

Large Frame Series MB and ME Torqmotor housings require the use of the bearing mandrel shown in figure 2 on page 7 to press bearing 1191 into the housing to a required depth of .290/.310 inches 17.37/7,87 mml from the outside end of the bearing counterbore. SEE FIGURE 34.

Figure 34

20

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 bearinglbushing into the housing.

CAUTION

CAUTION: If the bearing. mandrel specified on page 7 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.

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.

CAUTION

Figure 36

press in inner bearing/bushing

2.

The Small Frame Series MG and MF Torqmotor inner housing bearing/bushing 1131 can now be pressed into its counterbore in housing 118) flush to .03 inch 1.76 mml 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 1191. Reference figure 1, page 7. SEE FIGURE 36.

Figure 37

The Large Frame Series MB and ME Torqmotor housing 11 81 requires that you assemble a new backup washer (171, new backup washer 1251, new seal 1161, with the lip faCing out, new thrust washer (141, new thrust bearing 1151 and a new second thrust washer 1141 in that order before pressing in the inner housing bearing 1131.

SEE FIGURE 37 & 38. When these components are in place, press new bearing 1131 into the housing (181 to a depth of .105/.125 inches 12.67/3.181 below the housing wear plate contact face. Use the opposite end of the bearing mandrel used to press in outer bearing (191. Reference figure 2, page 7. SEE FIGURE 39.

Figure 38 21

press in dirt & water seal

3.

Apply a small amount of clean grease to a new dirt and water seal 1201 and press it into the housing 1181 outer bearing counterbore.

The Small Frame Series MG and MF Torqmotor dirt and water seal 1201 must be pressed in until its' flange is flush against the housing.

SEE FIGURE 40.

The Large Frame Series MB and ME Torqmotor dirt and water seal 1201 must be pressed in with the lip facing out and until the seal is flush to .020 inches 1.51 mml below the end of housing.

SEE FIGURE 41.

Figure 39

Figure 40

Figure 41

place housing assembly into vise

4.

Place housing 1181 assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. SEE FIGURE 42.

Figure 42

22

assemble backup washer & seal

5.

On Small Frame, Series MG & MF Torqmotors assemble a new backup washer 1171 and new seal (16) with the seal lip facing out, into their respective counterbores in housing (18) if they were not assembled in procedure 2. large Frame, Series MB and ME Torqmotor housing 1181 that did not require replacement of the bearing package will require that the two "captured" thrust washers 1141 and thrust bearing 1151 be unseated and vertical to the counterbore and the new backup washer 1171, new backup washer 1251, and new seal 1161 be worked around the thrust bearing package and placed into their respective counterbores. The seal lip must face out of the seal counterbore. Be sure the thrust bearing package is reseated correctly after assemblv of the seal and backup washer.

SEE FIGURE 43 & 44.

Rgure 43

CAUTION: Original design large Frame, MB & ME Torqmotors that do not have backup washer (25) when disassembled must be assembled with a new backup washer (17), new backup washer (25), and new seal (16).

CAUTION

Figure 44

assemble thrust washer & bearing

6.

Assemble thrust washer (14) then thrust bearing {l5) that was removed from the Series MG or MF Torqmotor. SEE FIGURE 45.

NOTE: Small Frame Series MG and MF Torqrnotors require one thrust washer (141 with thrust bearing (15). The coupling shaft will be seated directly against the thrust bearing.

NOTE

Figure 45

applv masking tape to shaft

7.

Apply masking tape around splines or keyway on shaft 1121 to prevent damage to seal.

SEE FIGURE 46.

Figure 46

23

install coupling shaft

8.

CAUTION

Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower louterl housing bearing/bushing 1191. Install the coupling shaft 1121 into housing 1181, seating it against the thrust bearing (151 in MG and MF Series housings and against the second thrust washer 1141 in MB and ME Series housings.

SEE FIGURE 47.

CAUTION: The outer bearing (19) is not lubricated by the system's hydraulic fluid. Be sure it is thoroughly packed with the recommended grease, Ross Gear grease specification #045236, ElM lubricant #K·70M.

NOTE: The coupling shaft (12) will be flush or just below the housing wear plate surface on Small Frame, Series MG and MF Torqmotors when properly seated while the coupling shaft (12) on large Frame, Series MB and ME 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.

NOTE

install thrust bearing

-9.

Install thrust bearing 1111 onto the end of coupling shaft 1121 only if you are servicing an MB or ME Series Torqmotor. SEE FIGURE 49.

insert seal ring

10.

Apply a small amount of clean grease to a new seal ring 141 and insert it into the housing (181 seal ring groove. SEE FIGURE 50.

Figure 47

Figure 48

Figure 49

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.

Figure 50

24

install drive link

11.

Install drive link 11 OJ the long splined end down into the coupling shaft 1121 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.

NOTE

Figure 51

assemble wear plate

12.

Assemble wear plate 19) over the drive link 1101 and alignment studs onto the housing 11Sl. SEE FIGURE 52.

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 IS81. SEE FIGURE 53.

install the assembled rotor set

14.

Install the assembled rotor set 18) onto wear plate 19) with rotor ISA) 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 (1) over the drive link.

NOTE

NOTE: If necessary, go to the appropriate, "Rotor Set Component Assembly Procedure," on page 30 or 31.

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 has a seal ring groove on the wear plate contact side of the stator 18B).

Figure 53

Figure 54

25

assemble seal ring in manifold

15.

NOTE

assemble manifold

Apply clean grease to a new seal ring 141 and assemble it in the seal ring groove in the rotor set contact side of manifold m. SEE FIGURE 55.

NOTE: The manifold (7) is made up of several plates bonded together permanently to form an integral component. The manifold surface that must contact the rotor set has it's series of irregular shaped cavities on the largest circumf,rence 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 171 over the alignment studs and drive link 11 01 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 141 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 161 over alignment studs onto the manifold. SEE FIGURE 58.

Figure 58

26

assemble seal & commutator

19.

Assemble a new seal ring 131 flat side up, into commutator 151 and assemble commutator over the end of drive link 1101 onto manifold 17) with seal ring side up. SEE FIGURE 59, 60.

Figure 60

assemble shuttle valve parts into

20.

end cover

If shuttle valve components items #21, #22, #23, #24 were removed from the end cover 121 turn a plug 1211 with a new a-ring 122), loosely into one end of the valve cavity in the end cover. Insert a spring 1231 the valve 124) and the second spring 1231 into the other end of the valve cavity. Turn the second plug 121) with a new a-ring (22) loosely into the end cover valve cavity. 3116 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 12) assemble a new a-ring 122) on the two plugs 1211. Assemble a two piece relief valve 124) 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.

Figure 62

27

assemble seal ring & end cover

22.

Assemble a new seal ring 141 into end cover 121 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 1181. The correct 5 bolt end cover bolt hole relationship to housing port bosses is shown in FIGURE 65.

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.

NOTE

Figure 63

Figure 64

Figure 65 assemble cover bolts

23.

Assemble the 5 or 7 special bolts 11, 1A, 1B or 1CI 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. Ibs. 130-35 N ml for the five MG & MF Series 5116 24 threaded bolts or 45-55 ft. Ibs. 161-75 N mI for the seven MB & ME Series 3/8-24 threaded bolts. SEE FIGURE 66,

67, 68.

28

Figure 66

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 end cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required.

NOTE

Figure 67

Figure 68

torque the valve plugs

24.

Torque the two shuttle valve plug assemblies 1211 in end cover assembly to 9-12 ft. Ibs. 112·16 N ml if cover is so equipped. SEE FIGURE 69.

Torque the two relief valve plug assemblies 1211 in end cover assembly to 45-55 ft. Ibs. 161-75 N ml if cover is so equipped.

THE ASSEMBLY OF THE TORQMOTOR IS NOW COMPLETE EXCEPT FOR WOODRUFF KEY 112A1, NUT 112BI, WASHER 112CI, BOLT 11201, LOCKWASHER 112£1, RETAINER RING 112FI or PORT a-RINGS 118AI AT INSTALLATION IF APPLICABLE. SEE PAGE 33 FOR FINAL CHECKS.

Figure 69

29

Rotor Set Component Assembly Procedure One Piece Stator Construction A disassembled rotor 18A) stator 1S81 and vanes I8C) that cannot be readily assembled by hand can be assembled by the following procedures. assemble stator

1.

Place stator 18B) onto wear plate 191 with seal ring 141 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 111 finger tight into bolt holes approximately 180 degrees apart to retain stator and wear plate stationary.

assemble rotor

3.

assemble vanes

Assemble the rotor 18AI, counterbore down if applicable, into stator 1881, and onto wear plate 191 with rotor splines into mesh with drive link 1101 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.

NOTE

4.

Rgure 71

Assemble six vanes 18Cl, 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.

CAUTION

Figure 70

assemble full complement of vanes

5.

Grasp the output end of coupling shaft 1121 with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes IBCI into stator IBBl, 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 111 if used to retain stator and wear plate.

Figure 72

Go to Torqmotor assembly procedure #15, page 26 to continue Torqmotor assembly.

Rgure 73 30

Rotor Set Component Assembly Procedure Two Piece Stator Construction A disassembled rotor set 181 that cannot be readily assembled by hand and has a two piece stator can be assembled by the following procedures. assemble stator halfs

1.

Place stator half ISBI onto wear plate (91 with seal ring 141 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 bolt holes 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 IBAI, counterbore down if applicable, into stator half 18BI, and onto wear plate 191 with rotor splines into mesh with drive link 1101 splines.

NOTE

..~ssemble ~

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.

vanes

4.

Assemble six vanes (BCI. 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.

CAUTION

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 (BCI into stator half laBI, 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 1801 on a flat surface with seal ring groove up. Apply a small amount of grease to a new seal ring 141 and assemble it into stator half ring groove.

31

assemble second stator half

7.

CAUTION

Assemble the second stator half 1801 over the two alignment studs and rotor 18AI with seal ring side down onto the first stator half 1881 aligning any timing marks applied for this purpose.

CAUTION: If the stator half (8B) is a different height (thickness) than stator half (80) 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 18EI, 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 1121 with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes IBEI into stator 1801, creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

Go to TorQmolor assembly procedure #15, page 26 to continue ToTQmotor assembly.

32

Final Checks

Final Checks •

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

•

Check TorqmotorM for rotation. Torque required to rotate coupling shaft should not be more than 50 ft. Ibs. 168 N mt

•

On MG & MF Series Torqmotors, pressure port with "A" cast under it on housing 118) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with "8" cast under it is for counter clockwise coupling shaft rotation.

•

On M8 & ME Series Torqmotors, pressure port with "8" cast under it on housing 1181 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'M .

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: 00 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 2000F 193.3°CI.

33

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 TorqmotorM component. Replace the component with original equipment only.

•

Do not cold straighten, hot straighten, or bend any TorqmotorM part.

•

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

•

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

•

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

CAUTION: Do not weld, braze, solder or any way alter any Torqmotor™ component.

CAUTION: Maximum operating pressure must not exceed recommended TorqmotorM 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.

Ross Gear extends close technical cooperation and assistance. If problems occur which you cannot solve, please contact our Ross Service Department or local Ross approved Distributor.

Our phone number and telex number and address are on the back cover of this manual.

34

Application Data MG Series

MG MG English

TO'!lRIOto, Series Displacement

Pressura (PSI) (kg/em')

(ill'lraw) (em'/rev) Continuous (differential)

Metric

1. 3

Intermittent (differential) I. 3. 4 At continuous rated pressure and flow

Torque U...lbs) Ikg·ml

(GPM) liiters/minl

Speld (rpm)

03 3.0

04 4.0

05 5.0

0& 6.0

08 8.0

10 10.0

12 12.0

14 14.0

16 16.0

18 18.0

20 20.0

41

49

66

82

98

131

164

197

229

262

295

328

1500

1500

1500

1500

1580

1500

1500

1500

1500

1200

1100

1000

105.5

105.5

105.5

105.5

105.5

105.5

105.5

105.5

105.5

84.4

71.3

70.3

2300

2300

2200

2200

2000

2000

2000

2000

2000

1500

1400

1400

161.7

161.7

154.7

154.7

140.6

140.6

140.6

140.6

140.6

105.5

96.5

96.5

424

526

111

914

1083

1488

1831

2175

2549

2180

2233

2133

4.68

S.06

8.19

10.53

12.48

17.14

21.16

25.06

29.37

25.12

25.73

24.57

At intermittent rated pressure and continuous rated flow

107

819

1106

1381

1581

2044

2515

3495

2924

2993

3411

8.15

10.13

12.14

15.98

17.29

23.55

28.98

Minimum starting at continuous rated pressure

180

365

318

518

108

1131

1414

3028 34.89 1755

Minimum starting at intermittent rated pressure

Flow

02 2.5

Continuous Maximum At continuous rated flow & pressure At maximum flow and no load 2

40.27

33.69

34.48

39.30

2011

1892

1770

1655

2.07

4.21

4.36

5.97

8.16

13.03

16.29

20.22

23.24

19.49

20.39

19.07

331

642

689

883

1082

1586

2058

2418

2141

2294

2364

2676

3.88 9 34

7.40

10.17

12.24

18.27

23.71

27.86

31.58

26.43

27.24

30.83

9

12

12

12

12

12

12

34

45

45

45

45

45

45

45

9

9

9

9 34 375 406

12

15

15

12 45 15

12

34

7.94 9 34

15

15

15

15

9

34

34

34

112 194

631 681

491 511

45

57

57

57

57

57

57

57

430 454

324 430

263 342

219 284

189 248

164 212

149 191

132 16&

Notes: 1. The maximum pressure at the motor inlet or outlet ports without regard to the continuous or intermittent pressure ratings is 2300 PSI 1161.7 kg/cm 2J. 2. For applications with rpm requirements in excess of the maximum rating contact your authori.zed Ross Gear representative.

3. Differential pressure is the difference between inlet and outlet port pressures.

4. Intermittent pressure applies to a maximum of 10% of every minute.

5. Operating Temperature: Recommended - 20 OF to 200 OF. 6. Filtration: Recommended nominal filtration is 20 to 50 micrometers.

7. Recommended fluid: lOW40 SE or SF API designation; 50 SUS minimum at maximum operating temperature; and .125% zinc antiwear by weight.

35

Application Data MF Series

MF 01.........

PmIunt (PSO

(kg/em'!

•EntIiIIa

Tarque (kg-ml

Flaw

Speed (rpm!

10 18.8

82

131

164

197

1750

1758

1758

1758

1758

12 12.8

,_ 14 14.11 229

I. 18 11.0 262

18 18.8

20 28.0

295

1.

84.4

328 1t00 77.3

llSO

1858

151.2

1311.1

1510

116.0

105.5

2451

2203 25.38

2285

2338

26.33

26.84

3412 39.89

3478

3427

Continuous Idiffarantial! 1. 3

1750

123.0

123.0

123.0

123.0

123.0

123.0

109.0

Intermittent (differential! 1. 3. 4

123.0 2500 175.8

123.0

2508

2511

2508

2508

2158

175.8

175.8

2508

2508

175.~

2588

115.8

175.8

515

818

1052

1285

2217

2_

9.40

12.12

14.80

1788

5.93

837 7.35

20.37

25.54.

30.05

28.33

778

.85

1244

1557

1883

2584

3291

3732

3498

8.94

11.1~

14.3~

17.94

21.69

29.77

37.92

43.01

40.30

Minimum starting at continuous rated pressure

229

498 5.71

845

878

1348

1843

20n

1894

2.64

447 5.15

7.43

10.12

15.44

18.93

23.15

21.82

21.12

Minimum starting at intermitteRt rated prassura

372

788

794

1824

1384

2511

3213

3831

8.13

11.80

9

12

12

12

12

15

15

34

34

45

45

23.88 12 45

28.93

9

9.15 12 45

37.02

3011

4.29

15.95

2073

45

57

57

12

15

15

15

15

15

15

20

21 76 Z8I

Metric

At intermittent rated pressure and continuous rated flow

Continuous Maximum At continuous rated flow & 2ressur8 At maximum flow and no load 2

Notes: 1. The maximum pressure at the motor inlet or outlet ports without regard to the continuous or intermittent pressure ratings is 2500 PSI 1175.8 kg/cm21.

2. For applications with rpm requirements in excess of the maximum rating contact your authorized Ross Gear representative.

3. Differential pressure is the difference between inlet and outlet port pressures.

4. Intermittent pressure applies to a maximum of 10% of every minute.

5. Operating Temperature: Recommended - 20 Of to 200°F. 6. Filtration: Recommended nominal filtration is 20 to 50 micrometers.

7. Recommended fluid: 10W40 SE or SF API designation; 50 SUS minimum at maximum operating temperature; and .125% zinc antiwear by weight.

36

01

8.0

1758

(cm'/revl

(GPM)

(liters/mini

08 1.0 98

05 5.0

83 3.8 49

(hI'/revl

At continuous rated pressure and flow

(I..l.IIII

04 4.11 66 1758

02 2.5 41

Tar!l!!!atar Series

175.8

•

175.8

45

34.69

34

45

57

57

57

57

57

57

76

898

824 913

888 888

501 882

421 578

320 438

259 342

218 284

243 328

794

91.4

,_ 35.00

285

39.98

39.48

1928

1993

22.21

22.96

2888

3007

32.95

34.64

15

15

57

57

20

20

76

76

188 257

184 228

Application Data MB Series

MB TOf9!!!!!!or Series

0isp1acalHnt

Pressure IPSO (kg/cm'l

(i.'/ml Icm3/revl

MI Et....

MetJ1:

Continuous Idilfarentiall 1. 3 Intermittent (differentiall 1. 3. 4 At continuous rated pressure and flow

Torque {f. . . .

Ikg·ml

At intermittent rated pressure and continuous rated flow Minimum starting at continuous reted pressure Minimum starting at intermillent rated pressure

Flow

Continuous

IGPMI

!liters/mini Speed

lrpml

Maximum At continuous rated flliw & !ressute At maximum flow and no load 2

IS 5.0 82 3000 210.9 4000 281.2

l1Z1 22.19 2563

29.53 1259 14.51 , ..3 19.16 12 45 15 57 476

784

88 U

98 2250 158.2 3_ 246.1 1727 19.90

2760 31.80 1144 13.18 1909 21.99 15 57 20 76 540 762

08 i 7.8 1~

2000 140.6 3_ 210.9 1973 22.73 3082 35.51 1370 15.18 2052 23.64 15 57 20

76 427 595

09 8.8 141 2_ 140.6 3000 210.9 2203 25.38 3451 39.76 1618 18.64 2541

29.28 15 57 20 16 385 534

10 10.2 167 2001 140.6 3000 210.9 2858

30.62

4030 46.43 2019 23.26 2985 34.39 15 57 20 76 315 443

12 12.1 198 2_ 140.6 3000 210.9 3143 36.21 4719 54.37 2342

26.98 3738 43.07 15 57 20 76 275 382

15 14.8 239 2_ 140.6 3000 210.9 3777 43.52 5992

69.04 3179 36.63 4930 56.80 20 76 25 95 301 395

18 17.7 290 2000 140.6 3000 210.9 4374 50.39 6941 79.97 3453 39.18 5284 6IJ.65 20 76 25 95 257 336

23 23.4 383 1400 98.4 2200 154.7 3860 44.47 6485 74.71 3150 36.29 5084 58.57 20 76 25 95 200 256

Notes: 1. The maximum pressure at the motor inlet or outlet ports without regard to the continuous or intermittent pressure ratings is 4000 PSI 1281.2 kg/cm21. , 2. For applications with rpm requirements in excess of the maximum rating contact your authorized Ross Gear representative.

3. Differential pressure is the difference between inlet and outlet port pressures.

4. Intermittent pressure applies to a maximum of 10% of every minute.

5. Operating Temperature: Recommended 0 to 200°F. 6. Filtration: Recommended nominal filtration is 20 to 50 micrometers.

7. Recommended fluid: 10W40 Sf Of SF API designation; 50 SUS minimum at maximum operating temperature; and .125% zinc antiwear by weight.

37

Application Data ME Series

ME ME

Torgmotor Series oil\llacement Pressure (PSI! Ikg/em'l

(in'/revl lema/revl

English Metric

Speed (rpml

18 17.7

21 28.&

29 29.0

33 32.6

48 48.1

58 58.0

198

239

290

338

475

534

788

950

Continuous Idifferentiall 1. 3

3000

3000

3000

2000

2000

1500

1000

210.9

210.9

210.9

210.9

3008 210.9

140.6

140.6

105.5

70.3

Intermittent Idifferentiall 1. 3. 4

4000

4000

4000

4000

4008

3000 210.9 7313

2500

2000

1500

At intermittent rated pressure and continuous rated flow Minimum starting at continuous rated pressure

Continuous Maximum At continuous rated flow & eressure At maximum flow and no load 2

Notes: 1. The maximum pressure at the motor inlet or outlet ports without regard to the continuous or intermittent pressure ratings is 4000 PSI 1281.2 kg/cm2!.

2. For applications with rpm requirements in excess of the maximum rating contact your authorized Ross Gear representative.

3. Differential pressure is the difference between inlet and outlet port pressures.

4. Intermittent pressure applies to a maximum of 10% of every minute.

5. Operating Temperature: Recommended 0 to 200°F. 6. Filtration: Recommended nominal filtration is 20 to 50 micrometers.

7. Recommended fluid: 10W40 SE or SF API designation; 50 SUS minimum at maximum operating temperature; and .125% zinc antiwear by weight.

38

15 14.6

141

Minimum starting at intermittent rated pressure Flow (GPMI lIiters/minl

12 12.1

3000

At continuous rated pressure and flow Torque Un·Lbsl Ikg-ml

09 B.6

281.2

281.2

281.2

281.2

2eU

3456

4699

5992

7061

8339

175.8

140.6

105.5

B326

8737

690B

39.82

54.14

69.04

81.35

96.08

84.25

95.93

100.66

79.59

4725

6434

8154

9619

1112&

12013

10735

11789

10954

54.44

74.13

93.94

101.82

128.18

138.40

123.68

135.82

126.20

2667

3313

4930

5600

6529

6287

7339

5733

30.73

38.17

56.80

64.52

75.22

72.43

84.55

66.05

3495

3889

6491

7552

8987

9678

7104 81.B5 8974

9313

8544

40.27

44.81

74.78

87.01

103.39

107.30

98.44

20

20

20

103.54 20

111.50

20

20

20

20

20

76

76

76

76

76

76

76

76

76

25

25

25

25

25 95 197 279

30

30

30

30

114

114

114

114

145 236

127 212

87 141

76 lIB

95

95

95

95

494 670

349 479

288 395

245 336

'6, MF, MB, ME Series Service Procedure

Write or can for information and added details concerning your installation and applications: Phone: Telex: Write:

317.423.5377 279413 TRW RII$S Gear ~n 800 Heath Street lafayette. Indiana 47902

MG.MF.MB.ME 101 WAl5M 9-91

TABLE OF CONTENTS

3172 J':IGURB

••••••••••••••••••••• Final Installation

10 ••......

21 ••••••••••.') ••••••••••••••••••••••• Electrical Diaqram 22 ••••••• '••

..... ............ .. .. .Hydraulic Schematic

30 •••••••••••••••••••••••••••••••••• Platform Installation 31 •••••••••••••••••••••••••••••••••• Platform Control Box Assembly 50 .•..•.............•..•..•........• List Installation

51 •••••••••••••••••• \ ••••••••••••••• Lift Cylinder Assembly

..... ••••••••• Safety Arm Stand Assembly

52 . . . . . . . . . . . . . . . . . .

70 ........................... ~assis Installation 71 •••••••.••••••••••••••••••• ~ ••••••• Hydraulic Pump Assembly 72 •••••••••••••••••••••••••••••••••• Limit Switch Assembly 73 .•..................•............. Fuel Tank Assembly

74......

• •••••••••••••••••••••••.• Eskridqe Brake Assembly

75 ••••••••.••••••••••••••••••••••••• Ground Control Box Assembly 76 •••••••••••••••••••••••••••••

•• Hydraulic Installation

77 ••••••••.••••••••••••••••••••••••• Hydraulic Manifold Assembly 78 •••••••••••••••••••••••••••••••••• Hydraulic Tank Assembly 79 •••••••••••••••••••••••••••••••••• steering Installation

.! )

FIGURE 10 FINAL INSTALLATION 7

10,

12

,

1 REF

SHOWN MODEL 3172&

1.:-.- " , , - I

® ... ","f','>,-

',,;

FIGURE 10 FINAL INSTALlATION I

T

.

E

CALAVAR PART NUMBER

134354 2192271 3:67793 4BOW31444 5iBOW36725 6 BOW312 01 7030-G5000-00 -8 FIGURE 21 -9 FIGURE 22 10001-05000-lA 11 001-04000-2A. 12 001-G5000-3B l-1358276 l-14 67470-001 1-15287-96456-00

DESCRIPTION

QUANl1TY

1 2345 Holder, Safety Manual Manual, Operation and Safety Clamp Washer, Flat Washer, SPL Lock Nut, Hex Set, Decals Diaqram, Electrical (See Fiq. 21) Schematic, Hydraulic (See Fiq. 22) Installation, Platform (See Fiq. 30) Installation, Lift (See Fiq. 50) Installation, Chassis (See Fiq 70) Paint Yellow Oil, Hydraulic Kit, 2WD Hose

1 1 1 1 1 1 1 1 1· 1 1 1 1 1 1

FIGURE 21 ELECTRICAL DIAGRAM

i..

cl

~@ @

,..:J

~

•

I &~ ~d~ .. i o=®on ~ ..l

i~ ~ af J: , '"

~

~

~

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>-

e

t3LG> ~t ...-,~

5rt ~ :I

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t~

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i

0

®

®r®

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l..l

.

l z

g

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t:s

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j

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i

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l.

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l:r:~ :I!'=t s. ...

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:ill

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t

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ft)

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~~,~ ". -c ~

I ..-.

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oil

~ . ... - ··. t® il

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!

WHEEL MOTORS FR().jT

VELOCITY FUSE

VELOCITY FUSE

STEER CYLINDER

- --I f - -I

LIFT CYLINDER

I

LIFT

~ ~

CYLINDER

-------

-----

- 1 pos 1TRAC _ :J VALVE I

--- l I

I

I I

OO\JN

VALVE

I

t-z1 .......

G1

FLOW CONTROLS FREE \JHEEL VALVE

EMERGENCY LOWERING VALVE

r-

REAR

CROSSRELIEF VALVES

OVER

I I I

~

~

~

~

~.

(j C/l

LIFT

VALVE SYSTEM RELIEF VALVE

BALL SHJT-OFF VALVE

[

DU.4P VALVE

LOY SPEED VALVE

-------------------~ RETlRN FILTER

RESERVOIR

..-+-..............

J

FIGURE 30 PLATFORM INSTALLATION 7

9

8

11

10

18

~/"

®

- ""

17

/ 16

lZ

13

FIGURE 30 PlATFORM INSTALlATION CALAVAR PART

I T

.

E

DESCRIPTION 12345

NUMBER

,

I Decal, Capacity 1,5.0.0 LBS 1 Decal, 3172 I Decal, COBDOR Tape, Orange and Red 37LF .o~.o-G4.o28-.o.o1 Weldment, Deck Frame i Weldment, Right Side Rear Guardrail i Weldment, Right Rear Guardrail Weldment, Left Rear Guardrail Weldment, Right Side Front Guardrail Weldment, Left Side Rear Guardrail .ol.o-~.o48-.o.o! Assembly, Platform Control Box (See Fig. 31) -'r Weldment ~ Front Guardrail i Weldment, Left Side Front Guardrail . Guard, Control Cable 392-.0.0.031-.0.01 Switch, Foot Clipper 164-.00.013-.0.01 Chain 245-.0.0.0.07-.00: Convert, Snap Plate 533-.0.0.0.01-.0.0 Link, Chain 'Weldment, Rear Movable Guardrail (option) BOW34272 Nut, Lock BOW314.o1 Washer, Flat BOW3.o.o.o6 ! Bolt, Hex BOW34113 i Rivet, Pop 245-.o.o.o.o8-0.oi Pin, Lanyard Hitch ' Assembly, Platform Floor

:L 52963

21 31 41 5 6 87,: 9 1.0 11 12: 13: 14, 15 16 17 18 19 20 21 22 23 24 -25

QUANlllY

37515 5.0277 58419

i

2 2 2

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

AIR AIR 1

i

FIGURE 31 PLATFORM CON1ROL BOX ASSEMBLY

5

® 17'

18

21

®

FIGURE 31 PlATFORM CONTROL BOX ASSEMBLY', I T

.

E

1.

CALAVAR PART NUMBER

DESCRIPTION

370-00001-0~t.. Recept~<:,t1.e,

_.Si.ncJ-le.;2l?,._3W

~-1'6'~q9JLQGQOL:-99.i.r:,. Devise. :W/~_Si~q~e Receptacle

31 "3"10-00;56-00; Decal, This Pluq 115 VC?It ~.----4i 3tO-OO~~i-OU Decal, Platform Operat1on Sheet 51 31.0-00159-00: Decal, caution Volt Lines 6; 310-00151-00! Decal, Read Instruction 7 324-00017-00 Relief, 3/4 strain '1 \ , ~ ... ooq 8: 331-00213-00 Nut, Lock ' ~ 9 324-00037-00 Relief, 1 Strain 1/;.. !/rC'OJ. w I.., 1 iI 4- 00

tr

10i 67124-003 11.'_~4.::.~~~2~-9.Ql_

Nut, Lock

P!:Uq )~~~ton..~ 12: .~~ ~.l:=!=..OO, .!!§.ldment., ... PlatformC;:ontrol ..Box 13, 620-G4105-00 • Panel, Platform Control 14 620-G4110-00 • Panel, Side 15' BOW36002 • Bolt, Hex 16 '6 (O - 001 ~~,Ou Decal, Platform Control Panel - '3'tts::l-<67 17 50075 .'_ ~.s.v..i:tph.J.D~ive, Lift, steer) .

18 392-=-O<r004-00 Switch, Speed .

'-~ ..

19,_ nS-,:.9_Q.o.o.~<!Q_ Kn~~ .. Emerqency stop Plastic 2CL»2.~.OO.015.::..Q.Ll!'itch, Push Pull 21,_ J92=-OJlQ2.1=.00-.sw.i.tchl-~h Pull ., _ ..

22; 157-99914-00- Rinq, Terminal I:; -7 - D.) J ., - ')J 23:! -157~00020-00: Rinq, Terminal , . ,• ., .• .•. - ..•••r.----I'" "~"

QUANnTY

12345 ,

1 1 1 1 1 1 1 1 1 1 1 1 1 1- .

6 1 3 1 1 1 1 3 13

FIGURE 50 LIFT INSTALIATION

5 -_ _

~

9

1

~~~~~~~--:

FIGURE 50 LIFT INSTALlATION I T

.

E

CALAVAR PART NUMBER

DESCRIPTION

QUANll1Y

1 23 45

1, 124-00028-00 Bushinq 2:' ~_QbQ~~~..:=ooi-C-am, 2 H Flower FoIl 0",1".1 c. j Iffl 3--!.~.§:~0001.~~ Bolt,..ft&x ~CA. -:.~or ~.tY\r

4 BOW34278

16 4

16 12 2

Nut, stop

5; 010-S4020-00i Weldment, Upper outer Arm / 6 010-54025-00 Weldment, Upper Inner Arm~ 7 010-54026-00 Weldment, Middle Inner"Arm

8 020-H5015-00Assembly, Lift CYlinder (See Fiq. 51) 010-54022-00 Weldment, Middle outer Arm 10 010-S4024-00 Weldment, Lower outer Arm 11 010-54027-00 Weldment, Lower Inner Arm12 010-54018-00 Weldment, Arm Stand (See Fiq. 52) 13 124-00030~O_..B.uahinq 14 _r6.E~0:OO~02~00... Collar,- Shaft 15 BOW40541 Screw, Set i ....... , 16 524-00006-00 Cable, Arm- 1\OT <; 9

-

{'1)/JI;oG ('~ Lt-

1 1 2 2 2 1 1 6 6 6 1

-=II- Sf&;l s dt) (iOYl), 1!I'.69;

. . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _....... t

FIGURE 51 LIFT CYUNDER ASSEMBLY 2

3

4

L------S

7

5'\-CSo S- -- \j A hH..

Co l~ W \('Y\<!)'o '{l:> (' 0 -vt ~ l ~{ ~ ~

V\t\ ~ I.l

>IrlJ

8

<!.'t l,'v..~~

PlLo~/(lc.ltc!(:. o AV-f.....

-9 I T

.

E

1 2 3 4 5 6 7 8 9

CALAVAR PART NUMBER 621-G9131-00 128-00026-00 331-0009B-00 162-96438-00 253-96618-00 154-00007-00 257-00001-00 253-96609-00 ~l ~-=1-q

DESCRIPTION

QUANllTY

1 2345 Pin, Lift Cylinder Bolt, Hex Nut, Esna (pM Assembly, Lift Cylinder ~ • Kit, Seal - i"0lt& - 0C03> Fittinq clamp, Hose FUse, Velcty Fittinq, Adapter

0 55J1h 00 .. ~ ~oW.e.L

~~~6

4 4 4

1 1 1 1 1 1 2..