Eaton Char-Lynn 10000 Series Owner's manual

October, 1997
Char-Lynn®
Hydraulic Motor
10 000 Series
Geroler®100deepSowT—rotoM
Repair Information

2
Parts Drawing
27 49 36 35
36 35
36
35
18 19 17
15 16 3
713 14 11 38
5
37 9
828
828
34
34a
1c
1b
1bb
1bbb
1a
1aa
12a 12b
41 —Bearingless Motor
50
Retainer inside bore of valve plate bearingless motors only
48 6
11
4
36
47
40
39
29
30
31
32
33
44 42
29
21 22 20
45 46
43
28
28
27
25
26
24
23
Ref.
No. Description Ref. No. Description
1a
1aa
1b
1bb
1bbb
1c Shaft S/A (2-1/8 in. 16T Involute Spline)
Shaft S/A (2-1/4 in. Tapered)
Shaft S/A (2-1/4 in. Str. w/o Thread)
Key (Str. Shaft)
Key (Tapered Shaft)
Nut (Tapered Shaft)
Thrust Washer, Rear
Whasher, Thrust
3
4
2 Spacer, Bearing
Whasher, Thrust
Thrust Bearing, Rear
Thrust Bearing, Front
Seal, Shaft
5
6
7
9 Bearing, Radial8
Spacer, Front Bearing
Washer, Backup
Housing, Bearing (Whl. Mtr. Mtg. Flange)
Housing, Bearing (Std. Mtr. Mtg. Flange)
10
11
12a
12b
Plate, Wear
Flange, Mounting /Wear Plate
18
Plug/O-ring S/A32
32a O-ring (Ref. No. 32)
Screw, Cap
16
Plate, Valve
17 Geroler
Plug/O-ring S/ARetainer, Front
Drive Plug/O-ring S/A
Ball
Spring
20 Valve
13
14
15
30
Balance Ring/Pin Assembly22 Spring21
31
19 Drive, Valve
33
33a
34
34a
Plug/O-ring S/A42
42a O-ring (Ref. No. 42)
Plug/O-ring S/A43
43a O-ring (Ref. No. 43)
Spool, Control44 Spring, Compression45 Spring, Compression46 Plug/O-ring S/A47
47a
O-ring (Ref. No. 33)
O-ring (Ref. No. 34)
41
Seal, Dust
Bolt (replaces and interchanges with studs)
O-ring37
38
39 Bolt (replaces and interchanges with studs)40
O-ring (Ref. No. 47)
O-ring23 Ring, Back-up24
Ring, Back-up26
Valve Housing29 Ring, Back-up28
O-ring25
O-ring27
O-ring49
Seal
Seal
35
36
Ref.
No. Description
Ring, Retaining48
Plug, Pipe50
See
Note 1
Note 1: Do Not
use spacer with
current replacement shafts
(Ref. No. 1). Motors with this
shaft spacer (6171-000) will still have
to be reassembled with spacer unless the
shaft was damaged and must be replaced.

3
Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
Figure 1
Tools Required:
- Torque Wrench, 165 Nm [120 lb-ft] * capacity
- 15/16, 1, and 1–1/4 inch sockets
- 5/32, 3/16, 5/16, and 5/8 inch hex keys
- 300 mm to 450 mm [12 to 16 inch] breaker bar
- Small blade screwdriver, 150 to 200 mm [6 to 8 inch] long
- Plastic or rubber hammer
Special Tools:
- Small internal bearing puller, sliding hammer type
- Output shaft sleeve
* Inch equivalents given in [brackets].
Disassembly
Cleanliness is extremely important when repairing hydraulic motors.
Work in a clean area. Before disconnecting the oil lines thoroughly
clean the port area of the motor. After the oil lines have been
disconnected, plug the motor’s ports to prevent dirt from entering.
Clean the exterior of the motor with a wire brush. Check the keyway
and chamfered area of the output shaft and remove any nicks, burrs,
or sharp edges that could damage the shaft seals during reassembly.
Drain the oil from the motor before beginning disassembly.
Note: On the standard and wheel motors the output shaft seal and dust
seal can be changed without completely disassembling the motor.
Steps 23 through 41 describe shaft and dust seal replacement. If
complete disassembly is planned, both the shaft seal kit and motor seal
kit will be needed. Refer to parts list 6-131 for seal kit part numbers.
1 Place the motor in a vise with the output shaft down. Clamp on the
motor’s mounting flange as shown in Figure 1. Protect the mounting
flange with soft vise jaws, wood, or hard rubber. Use just enough
clamping force to hold the motor securely during repairs. Excessive
force will distort the motor housing.
Note: Even though the motor is not shown in a vise in all the
drawings, it is recommended that the motor be kept clamped in a
vise during repairs.
2 Remove the four hex head bolts from the motor.

4
Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
Valve
Housing
Valve
Valve
Plate
Figure 2
Spring (4)
Balance Ring/Pins (2)
A, C, E, Back-up Ring
B, C, F, O-ring
Figure 4
A
BA
DC
E
F
3 Carefully lift the valve housing straight up. The balance ring should
lift away with the valve housing. The valve will remain on the valve
plate.
4 Set the valve housing on a clean work bench. Be sure to protect its
machined surfaces. Remove the 108 mm [4.25 in.] seal and 9,5 mm
[.375 in.] o-ring.
5 Remove the plug and o-ring from the port face. Remove the case
drain plug and o-ring from the bottom of the valve housing (see Figure 3).
6 Remove the balance ring and four balance ring springs. The
balance ring fits into the valve housing tightly. A sliding hammer
bearing puller may be needed to loosen it.
7 Remove the o-rings and back-up rings from the balance ring.
Note: Compressed springs under plugs, see step 8.
8 Carefully remove the two control spool plugs and o-rings.
9 Remove the control spool and springs.
10 Remove the two check ball plugs and o-rings. Remove the two
check balls and springs.
Disassembly
Valve
Housing
Plug/O-ring
Plug/O-ring
O-ring
Seal
Figure 3
Plug
Assembly
Plug with
Recess/
O-ring
Spring
Spool, Control
Plug/O-ring
Spring Spring
Ball, Check
Figure 5

5
Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
Valve
Valve
Plate
Valve
Drive
Figure 6
Seals
Valve
Plate
Seals
Figure 7
Splined
Drive
Thrust
Washer
Wear
Plate
Thrust
Bearing
Figure 8
11 Remove the valve.
12 Remove the valve plate.
13 Remove the valve drive.
14 Remove the Geroler. Be sure to keep the Geroler star and rollers
within the outer ring if they are loose.
15 Remove the 108 mm [4.25 in.] seal and 9,5 mm [.375 in.] o-ring
from each side of the Geroler.
16 Remove the splined drive.
17 Remove the wear plate.
18 Remove the rear thrust bearing and rear thrust washer. These parts
will either be on the wear plate or shaft bearings.
Disassembly
O-ring
Plug/O-ring Plug/O-ring
Seal
Figure 9

6
Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
Drive Spacer
Figure 10
Figure 11
19 Remove the 108 mm [4.25 in.] seal and 9,5 mm [.375 in.] o-ring
from the bearing housing.
20 Remove the two case drain plugs and o-rings from the bearing
housing.
21 Remove the bearing housing from the vise and turn it over so the
output shaft is on top.
22 The drive spacer may fall out of the output shaft (see Figure 10).
Watch for it! This spacer must be reinstalled when the motor is
reassembled.
Note: Some motors do not use a drive spacer.
23 Clamp the bearing housing in a vise so the output shaft is on top
(see Figure 11). Protect the bearing housing with soft vise jaws, wood,
or hard rubber. Use just enough clamping force to hold the bearing
housing securely while the retainer is removed.
24 Remove the eight cap screws that hold the retainer to the bearing
housing.
25 Carefully pry the retainer loose with a small blade screwdriver.
Do not damage the mating surfaces of the retainer or bearing housing.
26 Remove the 89 mm [3.5 in.] o-ring from the retainer.
27 Use a small blade screwdriver to pry the quad ring seal and back-
up washer from the retainer. Be careful not to damage the seal seat.
28 Turn the retainer over and pry out the dust seal with a small blade
screwdriver. Be careful not to damage the seal seat (see Figure 12).
29 Remove the output shaft.
30 Remove the thrust bearing and two thrust washers from the output
shaft.
31 Remove the bearing spacer.
Note: The shaft bearings are pressed into the bearing housing and
should not be removed. If the housing or bearings are damaged the
complete assembly must be replaced.
Disassembly
Cap
Screw
Retainer O-ring Quad Ring Seal
Dust
Seal Back-up Washer
Figure 12
Thrust Bearing
Thickest Washer
Thrust
Washers
Bearing Spacer
Figure 13

7
Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
Thrust Bearing
Thickest Washer
Thrust
Washers
Figure 14
Dust Seal
O-ring Back-up Washer
Retainer
Seal Replacement
Figure 15
Quad
Ring
Seal
Torquing Sequence
Figure 16
5
318
6
4
2
7
Check all mating surfaces and replace any parts with scratches or
burrs that could cause leakage. Wash all metal parts in clean solvent
and blow them dry with compressed air. Do not wipe parts dry with
paper towels or cloth as lint in a hydraulic system will cause damage.
Check the keyway and chamfered area of the output shaft and remove
any nicks, burrs, or sharp edges that could damage the shaft seals
during reassembly.
Note: Always use new seals when reassembling hydraulic motors.
Refer to parts list 6-131 for seal kit part numbers, replacement parts,
and ordering information.
Important: During reassembly lubricate the new seals with a
petroleum jelly such as Vaseline®. Also lubricate all machined
surfaces and bearings with clean hydraulic fluid.
32 Re-clamp the bearing housing in a vise with the mounting flange
up (see Figure 11). Remember, use just enough clamping force to
hold the bearing housing securely while the output shaft and retainer
are reinstalled.
33 Install the bearing spacer.
34 Lubricate the output shaft with clean hydraulic fluid and insert it
into the bearing housing. Rotate it as it is inserted.
35 Install the thrust bearing and thrust washers. Install the thick
thrust washer first, then the thrust bearing, then the thin thrust washer.
36 Press the dust seal into the retainer. The metal side of the dust
seal must face the retainer (see Figure 15). If a press is not available
carefully tap the dust seal into the retainer with a plastic or rubber
hammer.
37 Install the quad ring seal and back-up washer as shown in
Figure 15.
38 Apply petroleum jelly to the 89 mm [3.50 in.] 0-ring and install it in
the groove in the retainer.
39 Lubricate the inner edge of the dust seal and quad ring seal with
petroleum jelly.
40 Slide the retainer over the output shaft onto the bearing housing.
Important: Do not damage the seals. Use an output shaft sleeve to
protect the seals if available.
41 Install the eight cap screws and tighten them to 34 Nm [300 lb-in].
Follow the screw torque sequence in Figure 16.
Reassembly

8
Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
Figure 18
Case
Drain
Case
Drain
Wear
Plate
Thrust
Washer
Thrust
Bearing
Figure 19
Seals
Geroler
Seals
Case
Drain
Splined
Drive
Case
Drain
42 Reposition the bearing housing in the vise so the output shaft is in
the down position.
43 Install the two case drain plugs in the bearing housing drain holes.
Use new o-rings and tighten the plugs to 81-122 Nm [60-90 lb-ft].
44 Pour a small amount of clean hydraulic fluid into the bearing
housing and output shaft.
45 Reinstall the drive spacer*if it was dislodged during disassembly.
Use a long thin rod to guide the drive spacer into the output shaft.
*Note: Do not use spacer with current motors or replacement shafts.
Motors with this shaft spacer will still have to be reassembled with
this spacer unless the shaft was damaged and must be replaced.
46 Apply petroleum jelly to the 108 mm [4.25 in.] seal and 9,5 mm
[.375 in.] o-ring. Install each in the appropriate groove in the bearing
housing (see Figure 17).
47 Put the rear thrust washer and rear thrust bearing into the recess in
the wear plate. The rear thrust washer goes in first. Petroleum jelly
may be used to hold these parts in place while the wear plate is being
installed.
48 Install the wear plate so the rear thrust washer is against the shaft
bearings. Be sure to align the case drain holes.
Reassembly
Figure 17
O-ring
Plug/O-ring
Plug/O-ring
Seal
Drive Spacer
*

9
Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
49 Install the splined drive.
Note: On smaller displacement motors the splined ends of the drive
are different lengths. If this is the case the longer spines go into the
bearing housing.
50 Determine which side of the Geroler goes against the wear plate.
Install the 108 mm [4.25 in.] seal and 9,5 mm [.375 in.] o-ring in the
appropriate grooves in that side of the Geroler. Apply petroleum jelly
to the seal and o-ring before installation.
51 Install the Geroler on the wear plate. Be sure to align the case
drain holes.
52 Apply petroleum jelly to the 108 mm [4.25 in.] seal and 9,5 mm
[.375 in.] o-ring. Install each in the appropriate groove in the top side
of the Geroler.
53 Install the valve drive.
Motor Timing Timing a hydraulic motor involves three steps. The
direction the output shaft rotates is determined by timing.
Timing Step #1 Locate the largest open pocket in the Geroler and mark
its position.
54 Install the valve plate on the Geroler. Be sure to align the case
drain holes.
Timing Step #2 Locate the open slot in the valve plate that is in line
with the largest open pocket in the Geroler.
Timing Step #3 Align any one of the side openings in the valve with the
open slot in the valve plate that is over the largest open pocket in the
Geroler. Engage the valve with the valve drive by rotating it clockwise
until the spine teeth mesh (1/2 spIine tooth). This will provide standard
rotation when pressurized (see Figure 21).
To reverse rotation engage the valve with the valve drive by rotating it
counter clockwise until the spline teeth mesh (1/2 spine tooth).
55 Install the control spool and springs.
56 Install the control spool plugs with new o-rings. The springs will
need to be compressed to install the second plug.
57 Tighten the control spool plugs to 81 -122 Nm [60-90 lb-ft].
58 Install the plug in the port face. Use a new o-ring and tighten the
plug to 27-46 Nm [20-34 lb-ft] (see Figure 22).
Reassembly
Figure 20
Rotate Valve
Clockwise
1/2 Tooth to
Engage Spline
Case
Drain
Alignment
Reference
Only
Valve
Plate
Valve
Drive
Largest
Open
Pocket
Reference
Mark
Any One of
Eight Ports
Open to Outside
of Valve
Case
Drain
Geroler
Figure 22
Plug with
Recess/
O-ring
Plug/O-ring
Spool, Control
Plug/O-ringPlug/O-ring Spring Spring
Figure 21
Standard Timing

10
Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
Figure 23
Spring (4)
Balance Ring/Pins (2)
A, C, E, Back-up Ring
B, C, F, O-ring
A
BA
D
C
E
F
O-ring
Seal
Figure 24
Small Gap
Plate,
Valve
Valve Housing
Figure 25
Bolt Torquing Sequence
Figure 26
41
23
59 Install the case drain plug in the bottom of the valve housing. Use
a new o-ring and tighten the plug to 81-122 Nm [60-90 lb-ft] (see
Figure 22).
60 Install the o-rings and back-up rings on the balance ring. Install
the o-rings first then the back-up rings.
61 The largest o-ring has two back-up rings, one on each side. The
two smaller o-rings each have one back-up ring. The two smaller
back-up rings are installed closest to the small end of the balance ring.
62 Put the four balance ring springs into their holes in the valve
housing.
63 To aid the installation of the balance ring lubricate its o-rings and
back-up rings with petroleum jelly. Align the balance ring index pins
with the index holes in the valve housing. Push the balance ring into
the valve housing until it just touches the springs.
Important: Do not push the balance ring all the way down into the
valve housing.
64 Apply petroleum jelly to the 108mm [4.25 in.] seal and 9,5 mm
[.375 in.] o-ring. Install each in the appropriate groove in the valve
housing.
65 Carefully position the valve housing on the valve plate. Be sure to
align the case drain holes. There should be a small gap between the
valve housing and valve plate. This gap will be closed when the hex
head bolts are tightened.
66 Install the four hex head bolts and tighten them to 129-149 Nm
[95-110 lb-ft]. Follow the torque sequence in Figure 26.
67 Install the two check balls and springs.
Reassembly

11
Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
Plug
Assembly
Spring
Ball, Check
Ball, Check
Ball, Plug
Figure 27
Bearing Housing
Retainer
Seal
Back-up
Washer
Quad
Ring
Seal
Cap
Screw
Dust Seal
Figure 28
Mounting Flange/Wear Plate
Seal
Seal
Pipe Plug
Figure 29
Important: The motor shaft must be vertical when the check balls are
installed. This will insure that they seat properly (see Figure 27).
68 Install the two check ball plugs with new o-rings and tighten them
to 6,8-12 Nm [5-10 lb-ft].
Wheel Motor
A different bearing housing is used on wheel motors (see Figure 28).
Other than this the parts are the same and the same disassembly/
reassembly procedures apply.
Bearingless Motor
Bearingless motors are the same as standard motors without the shaft/
bearing assembly, and thrust bearings. The mounting flange replaces
the bearing housing and wear plate (see Figure 29).
Reassembly

Disc Valve Hydraulic Motor
10 000 Series
Geroler Motors—Two Speed
Each Order Must Include the Following:
How to Order Replacement Parts
1. Product Number
2. Date Code
3. Part Name
4. Part Number
5. Quantity of Parts
For Additional Literature Contact Eaton Corp. Hydraulics
Division 15151 Highway 5 Eden Prairie, MN 55344.
Specifications and performance Data, Catalog No. 11-878
Replacement Part Numbers and Kit Information:
10 000 Series Motors —Two Speed
Parts Information No. 6-131.
Char-Lynn
®
Product number
Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344
Product Number
119 0000 000
120 0000 000
121 0000 000
Product Line
Identification
Number
Product
Identification
Number
Engineering
Change
Code
Week of
Year 01
Thru 52
Last
Number
of Year
Date Code
00 0
Displ. cm
3
/r [in
3
/r] Product Number
ShaftMounting
480
[29.3]
665
[40.6]
940
[57.4]
345
[21.0]
Ports
2-1/4 Inch
Tapered
120-2013 -2014 -2015 -2016
1-5/16 O-ring
Wheel
Motor
119-2013 -2014 -2015 -2016
2-1/4 inch Straight
Standard
119-2001 -2002 -2003 -2004
1-1/4 Split Flange
1-5/16 O-ring
119-2021 -2022 -2023 -2024
119-2009 -2010 -2011 -2012
1-1/4 Split Flange
1-5/16 O-ring
2-1/8 Inch
16 T Splined
119-2017 -2018 -2019 -2020
1-5/16 O-ring
2-1/4 Inch
Tapered 119-2005 -2006 -2007 -2008
1-1/4 Split Flange
120-2005 -2006 -2007 -2008
1-1/4 Split Flange
2-1/4 inch Straight
121-2005 -2006 -2007 -2008
1-5/16 O-ring
Bearingless
121-2001 -2002 -2003 -2004
1-1/4 Split Flange
120-2009 -2010 -2011 -2012
1-1/4 Split Flange
2-1/8 Inch
16 T Splined
120-2001 -2002 -2003 -2004
1-1/4 Split Flange

© 2008 Eaton Corporation
All Rights Reserved
Printed in USA
Document No. C-MOLO-TS008-E
Supersedes 07-132
November 2008
Eaton
Fluid Power Group
Hydraulics Business USA
14615 Lone Oak Road
Eden Prairie, MN 55344
USA
Tel: [phone]
Fax: [phone]
www.eaton.com/hydraulics
Eaton
Fluid Power Group
Hydraulics Business Europe
Route de la Longeraie 7
1110 Morges
Switzerland
Tel: [phone]
Fax: [phone]
Eaton
Fluid Power Group
Hydraulics Business Asia Pacific
11th Floor Hong Kong New World Tower
300 Huaihai Zhong Road
Shanghai 200021
China
Tel: [phone]
Fax: [phone]