Eaton Char-Lynn S Series Owner's manual

November, 1996
Char-Lynn®
Hydraulic Motor
S Series
General Purpose Geroler®Motor 008 009 010
Repair Information

2

3
General Purpose Motors
S Series
Geroler Motors
Tools required for disassembly and reassembly.
• Torque wrench (34Nm [300 lb-in] capacity)
• 300-400mm [12-16 inch] breaker bar
• 5/16–12 point socket no. 5422 (Heavy Duty— 56Nm [500 lb-in]
capacity)
• 5/16–12 point socket no. 5422 (Heavy Duty— 56Nm [500 lb-in]
capacity)
• Small screwdriver (150-200 x 6mm [6-8 x .25 inch] flat blade), see
page 6 for tooling information.
• 3/16 inch [5mm] hex key
• Shaft pressure seal installation tool for -008 motor P/N 600470
• Shaft pressure seal installation tool for -009 and -010 motors P/N
600523
• Seal sleeve or bullet P/N 600304 (1 inch dia. shaft), P/N 600466
The following tools are not necessary for disassembly and
reassembly but are extremely helpful.
• Small propane torch
*Tools available—by special order—through our service department.
Seal
Seal
Seal
Cap Screw
Housing
Drive
Spacer Plate
Geroler
End Cap
Drive Spacer
(Not Used on
-010 Motors)
Seal Plug
(Not Used on -010 Motors)
Seal Washers
(Not Used with
6 Point (E10)
Drive Screws)
Cap
Screw
Exclusion
Seal
Mounting
Flange
Back-Up Ring
(-009 and -010
Motors)
Pressure
Seal
Seal
Bearing
Race
Needle
Thrust
Bearing
Output
Shaft
Key

4
Figure 1
Figure 2
Seal Washer
Cap
Screw
End CapSeal
Figure 3
Geroler
Drive
Spacer
Seal
General Purpose Motors
S Series
Disassembly
Cleanliness is extremely important when repairing these motors.
Work in a clean area. Before disconnecting the lines, clean port area
of motor. Remove key when used. Check shaft and key slot, remove
burrs, nicks or sharp edges and polish around the key slot. Before
starting disassembly, drain oil from motor, then plug ports and
thoroughly clean exterior of motor.
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.
1 Place motor in vise, clamp across edge of flange with output shaft
down. When clamping, use protective device on vise, such as special
soft jaws, pieces of hard rubber or board, see Fig. 1.
2 Some motors may have a case drain plug in the end cap. If
external case drain is not used, it is not necessary to replace the seal
unless leakage occurs.
3 Remove cap screws and seal washers from end cap (seal washers
used on 59, 69 and 95 cm3/r [3.6, 4.2 and 5.8 in3/r] displacement
motors only).
4 Remove end cap.
5 Remove seal from Geroler.
6 Remove Geroler—retain rollers in the outer Geroler ring, see Fig. 3.
7 Remove seal from Geroler, see Fig. 3.
8 Remove drive spacer (not used on 95 and 159 cm3/r [5.8 and 9.7
in3/r ] displacement motors for the -008 and -009 motors and not used
on -010 motors).

5
Figure 4
Spacer
PlateDrive
Seal
Figure 5
No No
YesYes
13mm [.50 inch]
Clamp across portsnot across housing. Excessive
clamping pressure causes distorsion.
13mm [.50 inch]
Figure 6
Small
Propane
Torch
Mounting Flange
Cap
Screw
General Purpose Motors
S Series
Disassembly
9 Remove spacer plate.
10 Remove drive, see Fig. 4.
11 Remove seal from housing.
12 Reposition motor in vise. Clamp across ports as shown in Fig. 5,
not on side of housing. Do not over tighten jaws. Excessive clamping
force may distort housing.
13 Remove the 4 cap screws from the mounting flange. These motors
are assembled using Loctite on the screws to hold them in place.
The screws will require approximately 34-45Nm [300-400 lb-in] of
torque to break loose and approximately 11 Nm [100 lb-in] torque to
remove after they are broken loose. Do not use an impact wrench on
Loctited screws, this may result in rounded heads or broken sockets.
Note: If higher torque than given above is required to break the screws
loose, apply heat according to the following instructions. When heated
the Loctite partially melts and the torque required to remove the screw
is greatly reduced. Follow the instructions carefully, and be careful not
to overheat and cause damage to the motor. Use a small flame
propane torch to heat a small area of the housing, where the screw
enters, see Fig. 6. Apply torque to the screw with a socket wrench
gradually as heat is applied for 8 to 10 seconds. As soon as the screw
breaks loose, remove heat from the housing and continue turning the
screw until it is completely removed.
14 Remove motor from vise. Place on clean flat surface. Carefully lift
flange from housing with a twisting motion.

6
Figure 7
Bend Tip
Modify
Screwdriver
As Shown.
Remove all
Burrs. Radius on End
Radius
Pressure Seal
Exclusion Seal
Back-Up Ring
Mounting
Flange
Seal Removal Tool
Figure 8
Figure 9
Dust Seal
Back-up Ring (-009 and -010 Motors)
Mounting Flange
Pressure Seal
Oil
Seal
Figure 10
General Purpose Motors
S Series
Disassembly
15 The dust seal, pressure seal and oil seal will come off with the
flange. Use a seal remover tool, like the one shown in Fig. 7, to
remove the dust seal and pressure seal, as shown in Fig. 8 and 9.
Work nose of tool between pressure seal and flange. Pry seal partway.
Remove tool and repeat at a point 180°away. Push seal completely
out of cavity, see Fig. 8.
16 Remove output shaft from housing.
17 Remove bearing race and needle thrust bearing from shaft.
18 Some older housings have plugs. To remove the plug, use a 5mm
[3/16 inch] hex key, inserted through port opening, to push them out.

7
Figure 11
General Purpose Motors
S Series
Reassembly
Check all mating surfaces. Replace any parts that have scratches or
burrs that could cause leakage or damage. Clean all metal parts in
clean solvent. Blow dry with air. Do not wipe parts with cloth or paper
towel, lint or other matter can get into the hydraulic system and cause
damage. Check around the key slot and chamfered area of the shaft
for burrs, nicks or sharp edges that can damage the seals when
reassembling. Remove nicks or burrs with a hard smooth stone (such
as an Arkansas stone). Do not try to file or grind motor parts.
Note: Lubricate all seals with petroleum jelly such as Vaseline. Use
new seals when reassembling the motor. Refer to parts list (No. 6-
125) for proper seal kit number.
Important: Do not stretch seals before installing. Cleanliness is
extremely important in the successful application of Loctite. Use the
following procedures to properly clean all parts.
A. Wash the housing with non-petroleum base solvent to remove oil,
grease and debris. Petroleum base solvents may leave residue
detrimental to successful Loctiting. Pay particular attention to 4
tapped holes on the flange end.
Note: Fully cured Loctite resists most solvents, oils, gasoline,
kerosene, and is not affected by cleaning operations.
B. Blow dry with compressed air. Clean and dry the tapped holes.
Note: It is not necessary to remove the cured Loctite that is securely
bonded in the tapped holes; however any loose particles of cured
Loctite should be removed.
C. Wire brush the screw threads to remove cured Loctite and other
debris. Discard any screws that have damaged threads or a corroded,
damaged, or rounded head.
D. Wash the screws with non-petroleum base solvent. Blow dry with
compressed air jet.
19 If you removed check valves, or plug(s), replace seal(s). Lubricate
new seal(s). Install on check valves, or plug(s). Carefully push check
valves, or plug(s), in housing until flush with housing face. Do not
damage seal(s).
20 Lubricate output shaft with clean hydraulic oil, then install shaft in
housing.
Important: Do not permit oil to get into the 4 tapped holes.
Note: To help with timing procedures, a timing dot is machined on
output shaft, see figures 18 and 19.
21 Install needle thrust bearing then bearing race on shaft. Pull shaft
partially out of housing, push all three parts in housing together. The
bearing race must rotate freely when in position.

8
Place tip of applicator
at top of threaded
portion.
Apply 3 or 4
drops in
each hole.
Figure 14
Mounting
Flange
Seal
Driver
Seal
Tube
Back-up Ring
(No Back-up
Ring -008)
Seal Installation Tool
Fi
g
ure 13
Exclusion
Seal
Shaft
Pressure
Seal
Figure 12
Break Sharp
Corner (see
above note)
Mounting Flange Cross-section
15°
30°
,25/,51
[.010/.020]
Inspect for
cracks in this
area of seal
seat
General Purpose Motors
S Series
Reassembly
Important: Prior to installing high pressure shaft seal it is necessary
to break the sharp corner of the flange seal seat, see Fig. 12. Use
400 grit paper to break corner.
22 Clean mounting flange of all loose metallic chips, particles, dirt or
other contamination, including oil. During cleaning, visually check seal
seat in mounting flange for scratches or other marks that might
damage the pressure seal. Check for cracks in flange that might cause
leakage, see Fig. 12.
Important: If a pressure seal installation tool is not available,
temporarily install flange without seals. Then install 2 cap screws
to secure flange to housing. Install seals in flange, and apply
loctite, after you reassemble Gerotor end of motor (see step 41 thru
45 page 11).
Note: If you have a pressure seal installation tool, continue
reassembly, starting with step 23.
23 Lubricate I.D. of seal tube and 0.D. of shaft pressure seal with a
light film of clean petroleum jelly. Align small I.D. end of seal tube with
seal seat in mounting flange. Install back-up ring and pressure seal in
tube—lips of seal face up—see above. Then insert seal driver in tube
to firmly push (by hand with rotating action) seal in seal seat.
Important: After installing seal in flange, examine seal condition. If
cut, damaged, or improperly installed, you must replace it before
continuingreassembly.
24 Install dust seal in flange, see Fig. 15. Press the dust seal into place
carefully. To eliminate damage to rubber portion or distortion of metal
container use a tool (flat-round face 35-41mm[1.37 to 1.62 inch]
diameter) which provides proper guiding and positioning.
25 Install 1.94 inch [50mm] I.D. seal in flange.
Caution: Do not use excessive amount of Loctite.
26 Apply 3 or 4 drops of Loctite adhesive (Loctite no. 601 sealant) at
top of threads in each of 4 holes in housing, see Fig. 14. Do not allow
parts with Loctite applied to surface to contact any metal parts other
than their proper assembly. Wipe off excess Loctite from housing face,
using a non-petroleum base solvent. Do not apply Loctite to threads
more than 15 minutes before installing screws. If housing stands for
more than 15 minutes, repeat application. No additional cleaning or
removal of previous Loctite is necessary.

9
Dust Seal
Apply
petroleum
jelly across
this area, see
step 28.
This Lip
to Face
Inward
Interior
of
Motor
Output shaft
Bearing Race
Figure 15
Seal
Pressure
Seal
Back-up
Ring
(-009
and -010
Motors)
Figure 16
Spacer
PlateDrive
Seal
General Purpose Motors
S Series
Reassembly
27 Before installing the flange and seal assembly over the shaft, place
a protective sleeve or bullet over the shaft. Lubricate space between
dust seal and pressure seal, as well as lips of both seals, see Fig. 15.
Install flange. Rotate flange slowly while pushing down over shaft.
Be careful not to invert or damage the seals.
28 Clamp motor in vise as shown in Fig. 5, install dry screws and
alternately torque immediately to 28Nm [250 lb-in]. If you use
primer, allow to cure for 10-15 minutes, without primer, allow 6 hours
before subjecting motor to high torque reversals. On all other
applications you can run the motor immediately. If you use new bolts,
make sure they are the correct length, 22mm [.875 inch] under head
length, see parts list for correct part number. Longer screws will not
permit proper seal between the flange and housing. Install key in key
slot of shaft.
Geroler End
29 Clamp housing in a vise, Gerotor end up. See Step 1 for correct
clamping procedure.
Important: To aid installation of seals, apply light coating of clean
petroleum jelly, such as Vaseline, to seals before installing.
Important: Do not stretch seals before installing.
30 Pour approximately 35 cc of clean hydraulic oil in output shaft
cavity.
31 Install 90mm [3.59 in.] I.D. seal in housing seal groove. Avoid
twisting seal.
32 Install drive, observe proper timing procedure (Fig. 18).
33 Place spacer plate carefully on the housing, align bolt holes.
34 Install 90mm [3.59 in.] I.D. seal in Gerotor seal groove, see Fig. 17.
Avoid twisting seal.
35 Carefully place Gerotor on the spacer plate, see Fig. 17. Observe
proper timing procedure, see Fig. 18.
Figure 17
Geroler
Drive
Spacer
(Not Used
on -010
Motors)
Seal
Chamfer Side of Geroler Ring
Toward Spacer Plate
Counter Bore Side of Screw Holes
Toward End Cap

10
CCW CW
Figure 18
Standard Rotation Star Valley
Star Point
Threaded hole
for Timing Dot
Reference
Spacer Plate
Geroler
Timing Dot
Reverse Rotation
CCW
CW
Figure 19
Star Valley
Star Point
Threaded hole
for Timing Dot
Reference
Timing Dot
General Purpose Motors
S Series
Reassembly
Timing Procedure
A. Align shaft timing dot with any bolt hole.
B. Install drive. For the 59 and 74 cm3/r [3.6 and 4.5 in3/r] displace-
ments on the -010 motors, install the wide end of the drive in the
output shaft. Install either end of the drive in the output shaft for the
-010 motor displacements ranging from 97 to 370 cm3/r [5.9 to 22.6
in3/r].
C. Install spacer plate. Remember which bolt hole was aligned with
the shaft timing dot.
D. Place gerotor on wear plate, positioning any star point over the bolt
hole aligned with the timing dot.
E. Rotate gerotor to line up bolt holes. Be careful not to disengage star
from drive or disturb gerotor seal.
Reverse rotation is obtained by positioning any star valley, rather than
any star point, over the aligned bolt hole.
36 Install drive spacer (not used on 97 and 159 cm3/r [5.9 and 9.7 in3/r]
displacements on the -008 and -009 motors and not used at all on -010
motors). See figure 17.
37 Install 90mm [3.59 inch] I.D. seal in Geroler seal groove. Avoid
twisting seal.
38 Install end cap, see Figures 20 and 21.

11
Figure 20
Seal Washer
Cap
Screw
End CapSeal
General Purpose Motors
S Series
Reassembly
39 Install cap screws (and seal washers when required, see informa-
tion below) in end cap.
On 97 cm3/r [5.9 in3/r] displacement motors or less, use seal washers.
Pre-tighten all screws to 2-5 Nm[15-40 lb-in]. Make sure Geroler
section seals are properly seated before torquing screws. Then torque
screws to 23 Nm[200 lb-in] in sequence, as shown in Fig. 21.
On 120 cm3/r [7.3 in3/r] displacement motors or larger, omit seal
washers. Pretighten all screws to 2-5 Nm [15-40 lb-in]. Make sure
Geroler section seals are properly seated before torquing screws. Then
torque screws to 34Nm [300 lb-in] in sequence, as shown in Fig. 21.
Note: Steps 41 through 45 cover mounting flange seal installation
without using a seal installation tool.
40 Clamp motor in vise with output shaft up, see Fig. 23. Remove cap
screws and flange.
41 Prepare seal seat of flange, see step 22.
42 Lubricate dust seal O.D. Install dust seal in flange. Make sure dust
seal is flush with flange, see step 24.
43 Install pressure seal flush against bearing race, see Fig. 22. Lightly
lubricate pressure seal O.D.
44 Place a seal sleeve or bullet over shaft. Twist flange down shaft
until flush against pressure seal. The pressure seal must enter into
seat evenly and gradually. Install 4 cap screws. Gradually and evenly
finger tighten cap screws (crisscross pattern). Then use a hand socket
wrench to lightly snug tighten screws until flange is flush against
housing. Do not tighen screws more than one full rotation at a time
(crisscrosspattern).
45 Use a hand torque wrench to gradually and evenly tighten cap
screws (crisscross pattern) until they reach 28Nm[250 lb-in]. See
important information below.
Important: Do not use air socket wrench on cap scrdws for this type
of seal installation.
Important: Proper pressure seal installation is important. You must
remove cap screws and flange to examine seal condition. If you
have cut or damaged the pressure seal, you must replace it with a
new one. If seal is in good condition continue flange reassembly—
starting with procedure step 24, page 8.
Seal Sleeve
or Bullet
Pressure Seal Lips Toward Race
Figure 22
Back-up
Ring
(-009
and -010
Motors)
Lightly
Lubricate
Entire O.D.
of Pressure
Seal
Bearing
Race
Dust
Seal
57
1
3
2
4
6
Bolt Torquing Sequence
Figure 21
13 mm [.50 inch]
13 mm [.50 inch]
Figure 23

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.
103-1000-XXX Numbers 1001 through 1999 Standard Models
103-2000-XXX Numbers 2001 through 2999 Motors with Case Drain Port
Specifications and performance Data, Catalog No. 11-885
Replacement Part Numbers and Kit Information:
S Series Motors — Parts Information No. 6-125.
Char-Lynn
®
Product number
Eaton Corp. Hydraulics Div.
Eden Prairie, MN 55344
Product Number
103 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
General Purpose Motors
S Series

© 2008 Eaton Corporation
All Rights Reserved
Printed in USA
Document No. C-MOLO-TS010-E
Supersedes 07-116
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]