Eaton Char-Lynn 6000 Series Operating instructions

July, 1999
Char-Lynn®
Disc Valve Motor
6000 Series (includes Big 6)
Geroler®600-dna500-srotoM
Repair Information

2
6000 Series Char-Lynn Motors
Cross Section Drawing
-005 Version
Current Production
-006 Version
Char-Lynn
®
6000 Series Motor Bearing Package Change

3
6000 Series Char-Lynn Motors
Parts Drawing
Retainer, Front
Housing, Bearing
Screw, Cap
Bolt
Valve Housing
Valve Housing
(Split Flange Ports)
Seal Inner
Face
Seal
Outer
Face
Seal
Spring
Piston Shuttle
Seal
Balance
Ring
Valve
Valve
Plate
Seal
Valve
Drive
GerolerDrive
Geroler Seal
Seal Geroler
Shaft Face Seal
SealSeal Seal
Bearingless
Motor Mounting
Flange
Bearing
Housing
Wheel
Motor
O-ring
Plug Assembly
Poppet
Spring
Spring
Sleeve, Dash Pot
Sleeve, Dash Pot
Seal
Shaft Seal
Back-up
Ring (if
Supplied)
Shuttle (Two Way)
Seal
Shuttle Valve
Location when
Applicable
Dust Seal
Shaft and
Bearing Kit
(1-3/4 in.
Tapered) Key
Shaft and
Bearing Kit
(1-1/2 inch Straight)
Shaft and
Bearing Kit
(1-1/2 inch
17 Tooth Splined)
Plug
Assembly
Plug Assembly
Plug Assembly
Check
Valve
Plug
Assembly
Ball
Plug
Key
Dust Seal
Optional
Seal Guard
Retainer
-006 Retainer
-006
Spring

4
6000 Series Char-Lynn Motors
Tools
Tools required for disassembly and reassembly
—Torque wrench (90 Nm [800 lb-in] capacity)
—305 to 406 mm [12 to 16 inch] breaker bar
—3/4 inch and 1/2 inch sockets
—Small screwdriver (150 to 200 mm [6 to 8 inch] long,
6 mm [1/4 inch] blade)
—3/16 inch Hex Key
—Hydraulic Press — 1335 N [300 lbf]
—Plastic or rubber hammer
* —Bullet (600464) for 1-1/2 inch diameter shafts
*Available by special order through our service department.
9,52 [.375]
Grind flat spots on each side
Approx. 12,7 [.50]
215,9 [8.50]
(273,05 [10.75] required for 985 cm
3
/r [60.0 in
3
/r] Displ.)
Alignment studs (2)
25,4 [1.00]
1/2-20 UNF thread
12,7 [.50] Dia. Steel Rod
Wheel motor and bearingless motor repair information on page 12.
Shuttle valve and seal guard repair information on page 13.
Seal guard reference on page 13.
Shaft Face Seal
Dust Seal
Shaft Seal
Special Global Mount
Shaft and Bearing
Assembly Seal
Retainer, Front
Screw, Cap
Parts Drawing — Big 6

5
6000 Series Char-Lynn Motors
Disassembly
Cleanliness is extremely important when repairing a hydraulic motor.
Work in a clean area. Before disconnecting the lines, clean port area of
motor thoroughly. Use a wire brush to remove foreign material and
debris from exterior joints of motor. Check shaft and keyway, use 600
grit paper/cloth to remove all nicks, burrs, and sharp edges that might
damage the shaft seals when installing retainer on shaft and bearing
assembly. Before starting disassembly procedures, drain oil from
inside of motor.
1 Place motor in a vise with output shaft down. Clamp across edge
of bearing housing not on housing (see Figure 1). Excessive clamping
pressure on housing will cause distortion. When clamping, use some
protective device on vise, such as special soft jaws, pieces of hard
rubber or board.
Although not all drawings show the motor in a vise, we recommend
that you keep the motor in the vise during disassembly. Follow the
clamping procedures explained throughout the manual.
2 Remove 4 bolts (or nuts for earlier models) from motor. Remove
studs (earlier models) as shown in step 16.
3 Lift valve housing straight up. If done carefully, the springs and
balance ring subassembly will remain on valve for easy removal.
4 Carefully remove the following from the valve housing:
1 seal, 92,3 mm [3.63 inch] I.D.
1 seal, 7,6 mm [.30 inch] I.D.
2 check valve plug assemblies (plug, seal, spring, ball) 1 plug (case
drain) with seal.
5 Remove 3 balance ring springs.
6 Remove balance ring subassembly.
7 Remove inner and outer face seals from the balance ring.
8 Lift off valve.
9 Remove valve plate.
10 Remove 95,0 mm [3.74 inch] I.D. seal from valve plate
(see Figure 5).
11 Remove valve drive (see Figure 5).
Figure 1
Figure 2
Figure 3
Check Plug
Assembly
Plug
Assembly Valve
Housing
Seal
Figure 4
Spring (3)
Valve
Inner
Face
Seal Outer
Face
Seal Balance
Ring
Figure 5
Valve
Plate Seal
Valve Drive

6
6000 Series Char-Lynn Motors
Disassembly
12 Remove Geroler. Retain rollers in outer Geroler ring if they are
loose.
13 Remove 2 seals (6,1mm [.24 inch]) from Geroler, 1 seal on each
side of Geroler.
14 Remove drive.
15 Remove 95,0 mm [3.74 inch] I.D. seal from bearing housing.
16 Use a stud remover or vise grips to remove studs (earlier models
only). Then clamp bearing housing in vise as shown in Figure 7.
Loosen 6 bolts. Then remove bolts and retainer. You may have to pry
retainer free but do not damage housing or retainer.
17 Remove 92,3 mm [3.64 inch] I.D. seal, shaft seal and back-up ring
(if supplied) from retainer. Use a small screwdriver to remove dust
seal. Do not damage bore of retainer.
18 Remove shaft and bearing assembly. You may need a press to
remove shaft and bearing assembly (see Figure 10).
19 Remove shaft face seal from bore of bearing housing (see Figure
10). Do not damage bore of bearing housing.
Note: Individual parts of the shaft and bearing assembly are not sold
separately and must be replaced as a unit.
Figure 6
Seal
Seal
Drive
Geroler
Figure 7
Figure 8
Figure 9
Retainer
Dust Seal
Seal
Shaft
Seal
Back-up
Ring
Shaft and Bearing
Assembly
Shaft Face
Seal
Bearing
Housing
Figure 10

7
6000 Series Char-Lynn Motors
Reassembly
Check all mating surfaces. Replace any parts that have scratches or
burrs that couId cause leakage. Clean all metal parts in clean solvent.
Blow dry with air. Do not wipe with cloth or paper towel because lint
or other matter could get into the hydraulic system and cause damage.
Do not use a coarse grit papers/cloth or try to file or grind motor parts.
Check around the keyway and chamfered area of the shaft for burrs,
nicks, or sharp edges that can damage the seals when reassembling
the retainer.
Note: Lubricate all seals (prior to installation) with petroleum jelly
such as Vaseline®. Use new seals when reassembling the motor.
Refer to parts list (6-127 6000 Series -005 and 6-159 6000 Series -
006) for replacement parts and proper kit number.
20 Place bearing housing on smooth flat surface with largest open end
of housing up.
Apply petroleum jelly to shaft face seal. Install seal in seal seat. Seat
seal properly in groove (see Figure 11 and 14). A damaged or
improperly installed shaft face seal could cause internal lubrication
loss and subsequent parts wear.
21 Install shaft and bearing assembly in bearing housing (see Figure
12). Do not damage seal in bore of housing. You may need a press to
install shaft and bearing assembly.
22 Use a small press, if available, to install dust seal in retainer. Metal
side of dust seal must face toward retainer as shown in Figure 14. If a
press isn’t available, use a plastic or rubber hammer to tap dust seal in
place.
23 Install 92,3 [3.64] I.D. seal, back-up ring and shaft seal in retainer.
Flat or smooth side of shaft seal must face toward retainer as shown in
Figure 14. Apply petroleum jelly to inside diameter of shaft seal (after
installing seal).
24 Before installing retainer, place a protective sleeve of bullet (see
note below) over shaft. Grease inside diameter of dust and shaft seals.
To prevent damage to seals, install retainer over shaft with a twisting
motion. Do not cut or distort shaft seal. Damage to shaft seal will
cause external leakage.
Note: Bullet 600464 for 1-1/2 inch diameter shafts available—by
special order through our service department.
Figure 11
Shaft
Face
Seal
Seal
Seat
Bearing
Housing
Figure 12
Shaft and
Bearing
Assembly
Bearing
Housing
Figure 13
Retainer
Dust Seal
Seal
Shaft
Seal
Back-up
Ring
Figure 14
Bearing
Housing
Back-up
Ring Dust Seal Lip
Shaft and
Bearingless
Assembly
Shaft
Seal
Retainer
Seal
Shaft
Face
Seal

8
6000 Series Char-Lynn Motors
Reassembly
25 Lubricate threads of 6 bolts with a film of light oil. Install and finger
tighten all 6 bolts. Torque bolts to 6 Nm [50 lb-in] in sequence (see
Figure 15). Then final torque to 34 Nm [300 lb-in], in sequence.
Note: Full torque 34 Nm [300 lb-in] on one bolt at a time can
damage bolt or retainer.
27 Reposition motor in vise with output shaft down. Clamp across
edges of retainer as shown in Figure 16.
28 Pour a small amount of light oil inside the output shaft.
29 Install 2 studs (earlier models), diagonally opposed, in bolt holes of
bearing housing (see Figure 16). If you replace studs with bolts, use 2
studs for alignment purposes when stacking parts.
30 Apply a light film of petroleum jelly on 95,0 mm [3.74 inch] I.D.
seal. Install seal in bearing housing (see Figure 16).
31 Install drive in output shaft (insert longer splined end of drive first),
(see parts drawing on page 3).
32 Apply petroleum jelly on 2 seals, 6,1 mm [.24 inch] I.D. Install seals
(1 on each side of Geroler) in case drain grooves of Geroler.
Note: Installation at this point involves 3 steps in timing the motor.
Timing determines the direction of rotation of the output shaft.
Timing parts include:
1. Geroler
2. Valve drive
3. Valve Plate
4. Valve
Timing Step No. 1 — Locate largest open pocket in Geroler. Then
mark location of pocket on outside edge of Geroler (see Figure 17).
33 Align case drain hole and pressure relief hole in Geroler with case
drain hole and pressure relief hole in bearing housing. Install Geroler
on bearing housing (see Figure 17). Retain rollers in outer Geroler
ring if they are loose.
34 Install valve drive in Geroler.
35 Apply a light film of petroleum jelly on 95,0 mm [3.74 inch] I.D.
seal. Install seal in valve plate.
36 Align case drain hole in valve plate with case drain hole in Geroler.
Install valve plate (seal side toward Geroler) on Geroler as shown in
Figure 17.
Timing Step No. 2 — Locate slot opening in valve plate which is in
line with largest open pocket of Geroler (see Figure 17).
37 Use the following procedure for installing the valve on the valve
plate.
Timing Step No. 3 — Locate any one of the side openings of the valve
that goes through to the face of the valve. Line up this side opening
in the valve with open slot of valve plate that is in line with largest
open pocket of Geroler. Rotate valve clockwise (1/2 spIine tooth) to
engage valve with the valve drive spline, alignment reference shown in
Figure 17 (above). This procedure provides standard timing when
pressurized as shown in Figure 18 (below) .
16
4
2
5
3
Figure 15
Seal
Figure 16
Rotate Valve Clockwise
1/2 Tooth to Engage Spline
Valve
Valve
Plate
Alignment
Ref. Only
Note: Case Drain Holes (2)
Proper Alignment Shown Case Drain Hole Pressure Relief Hole
Anyone of 6 Ports
Open to Outside
of Valve
Largest Open
Pocket
Geroler
Figure 17 Timing Alignment
Figure 18
Counter
Clockwise
Rotation
Clockwise
Rotation
Standard
Timing Pressure In Pressure In

9
6000 Series Char-Lynn Motors
Reassembly
38 Apply clean grease on 3 balance ring assembly springs.
Install springs in 3 holes located inside bore face of valve
housing (see Fig. 19).
39 Apply a light film of petroleum jelly on 7,6 mm [.30 inch] I.D. seal.
Install seal in case drain groove of valve housing.
40 Apply a light film of petroleum jelly on 92,3 mm [3.63 inch] I.D.
seal. Install seal in outside seal groove of valve housing.
41 Apply petroleum jelly on inner and outer face seals. Install seals on
balance ring as shown in Figure 20.
Important: Install face seals in the positions shown in Figure 20 or
the motor will not operate properly. Do not force or bend these face
seals. Any damage to these seals will affect the operation of the
motor.
42 Align balance ring assembly pins with 2 holes in valve housing (see
Figure 21). Install balancing ring subassembly in valve housing.
43 Insert your finger through port of housing. Apply pressure to side
of balance ring assembly. Hold ring in position until valve housing is
in place (see Figure 21). Align case drain hole in housing with case
drain hole in valve plate. Install valve housing against valve plate (see
Figure 22).
Note: After installing valve housing on valve plate, check between
body parts of motor for unseated seals.
44 Install and finger tighten 2 bolts (or studs for earlier models)
opposite alignment studs. Remove alignment studs and install
remaining bolts (or studs and 4 nuts for earlier models). Torque bolts
(or nuts) to 98 Nm [864 lb-in/ 72 lb-ft], in sequence (see Figure 24).
45 Install 2 check plug assemblies (ball, spring, plug with seal). Also
install case drain plug with seal, parts shown in Figure 23 and plug
torque shown in Figure 24.
Figure 19
Seal Case Drain Seal
Valve Housing Balance Ring Spring (3)
Figure 20
Balance Ring
Inner SealPin Outer Seal
Figure 21
Figure 22
Figure 23
Bolt
Check
Plug
Assembly
Plug
Assembly
Figure 24
1
4
3
2
Char-Lynn
®
Product number
Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344
Check Plug Torque to
7-14 Nm [60-120 lb-in]
(lubricated Threads)
Drain Plug Torque to
17 Nm [150 lb-in]
(lubricated Threads)

10
6000 Series Char-Lynn Motors
Wheel Motors
A different bearing housing is used on wheel motors (see Figure 25).
Other than this, the parts are the same as the standard motor and the
same disassembly and reassembly procedures apply.
Bearingless Motors
This motor is the same as the standard without the shaft/bearing
assembly, bearing housing and retainer. The mounting flange replaces
the bearing housing (see Figure 26). Follow same disassembly and
reassembly procedures as rear section of standard motor.
Important: Loctite®information for bearingless motor below.
Important: This motor requires Loctite in threaded holes of
mounting flange.
Follow these procedures:
Adequate Loctite penetration and sealing depend highly on cleanliness
and dryness of threads. Use a non-petroleum base solvent to clean
excess oil from threads of flange after disassembly. You may need to
use a tap to clean threads of excess old Loctite. Then, after you have
fully reassembled the motor, apply 2 to 3 drops of Loctite no. 290 at
top of threaded holes (see Figure 27).
Note: Allow Loctite 5 minutes for thread penetration before installing
motor on gear case.
Figure 25
Bearing Housing
Key Seal Retainer
Bolt
NutDust Seal
Back-up Ring
(if supplied)
Shaft Seal
Figure 26
Drive
Seal Seal
Mounting
Flange
Figure 27
Attention:
Do not use more
than 3 drops of
Loctite on
threaded portion.

11
6000 Series Char-Lynn Motors
Motors with Shuttle
and, or Seal Guard
For More Detailed Information Contact Eaton Corp. Hydraulics
Division 15151 Highway 5 Eden Prairie, MN 55344.
Specifications and performance data, Catalog No. 11-878
Replacement parts numbers and kit information.
—Parts information 6-127 (for 6000 Series -005 and -006)
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
Char-Lynn
®
Product number
Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344
Product Number
000 0000 000
Product Line
Identification
Number
Product
Identification
Number
Engineering
Change
Code
Week of
Year 01
Thru 52
Last
Number(s)
of Year
Date Code
00 00
Piston
Poppet
Dash
Pot
Plug/O-ring
S/A (9/16-18)
Torque to
41 Nm [360 lb-in]
(Lubricated Thread)
Enlarged
Parts
Drawing
Plug/O-ring*
S/A (9/16-18)
Torque to
23 Nm [200 lb-in]
(Lubricated
Thread)
*Plug/O-ring S/A must be removed and
drain line added for shuttle valve operation.
Plug/
O-ring
S/A
Dash
Pot
Spring Spring
Poppet
Seal Guard Add-on Option
Seal Guard for
Current Production
-006 Version Only
Plug/O-ring
S/A (3/8-24)
Torque to
5 Nm [50 lb-in]
(Lubricated
Thread)
Optional
Seal Guard

Disc Valve Motors
6000 Series Motors
0221-7421-6121-5121-8121-7121-211
Standard
Displacement cm3/r [ in3/r ] and Product Number
ShaftMounting
310
[19.0]
390
[23.9]
490
[30.0]
625
[38.0]
737
[45.0]
-1219
800
[49.0]
985
[60.0]
Ports
50 mm Straight G 1 (BSP)
112-1215
Use digit prefix —112- plus four digit number from charts
for complete product number—Example 112-1215.
Orders will not be accepted without three digit prefix.
Product Numbers – 6000 Series (Big 6)
Mounting Type - Standard (Code H), 4 Bolt:
• 160,0 [6.30] Pilot Dia.
• 18,01 [.709] Dia. Mounting Holes
• 200,0 [7.87] Dia. Bolt Circle
Output Shaft - Straight (Code 21)
Ports - G1 (BSP) Staggered G 1/4 Case Drain (Code C)
Paint - Low Gloss Black
112-1064 -1065 -1066 -1067 -1068 -1107 -1069
1-1/2 inch Straight
Standard
Displacement cm3/r [ in3/r ] and Product Number
ShaftMounting
245
[ 15.0]
310
[19.0]
390
[23.9]
490
[30.0]
625
[38.0]
985
[60.0]
195
[11.9]
112-1058 -1059 -1060 -1061 -1062 -1109 -1063
Ports
112-1088 -1089 -1090 -1091 -1092 — -1093
114-1031 -1032 -1033 -1034 -1035 -1055 -1036
1-5/16 O-ring
Bearingless
Wheel
Motor
1-1/2 Inch
17 T Splined
112-1094 -1095 -1096 -1097 -1098 — -1099
40 mm Straight
114-1043 -1044 -1045 -1046 -1047 — -1048
G 1 (BSP)
1-3/4 Inch
Tapered 113-1070 -1071 -1072 -1073 -1074 -1093 -1075
1-5/16 O-ring
113-1082 -1083 -1084 -1085 -1086 -1100 -1087
40 mm Straight G 1 (BSP)
G 1 (BSP)
G 1 (BSP)
1-5/16 O-ring
1-5/16 O-ring
114-1047
Use digit prefix —112-, 113-, or 114- plus four digit number from charts
for complete product number—Example 114-1047.
Product Numbers—6000 Series Motors

© 2008 Eaton Corporation
All Rights Reserved
Printed in USA
Document No. C-MOLO-TS009-E
Supersedes 07-119
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]
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Fluid Power Group
Hydraulics Business Asia Pacific
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300 Huaihai Zhong Road
Shanghai 200021
China
Tel: [phone]
Fax: [phone]