White D9 800 Series Setup guide

Repair Instructions
D9 800 & 801 Series

Contents
Chapter 1: D9 800 & 801 Series Diagram...............................................................5
Exploded View......................................................................................................................................................6
Chapter 2: D9 800 & 801 Series Service Instructions............................................9
Seal Kit Installation.............................................................................................................................................10
Chapter 3: D9 800 & 801 Series Parts Listing......................................................13
Replacement Kits................................................................................................................................................ 14
Orbital Motors | Contents | iii

Chapter
1
D9 800 & 801 Series Diagram
Topics:
• D9 800 & 801 Series Exploded
View

D9 800 & 801 Series Exploded View
Exploded View Diagram
7
16
18
8
20
22
23
11
13
14
15
17
19
9
21
10a
12
7
10
2
1
3
5
4
6
Component List
Description Item Number
Housing seal 1
Dust seal 2
Seal carrier insert 3
O-ring seal 4
Backup shim 5
Quad seal 6
Body seal 7
Large piston seal 8
Small piston seal 9
Housing/shaft assembly (housing) 10
Housing/shaft assembly (shaft) 10a
Drive link 11
Orbital Motors | D9 800 & 801 Series Diagram | 6

Description Item Number
Bearing spacer 12
Wear plate 13
Rotor assembly 14
Driver 15
Manifold 16
Pin 17
Commutator 18
Piston 19
Piston springs 20
Endcover 21
Assembly bolt 22
Shaft key 23
Orbital Motors | D9 800 & 801 Series Diagram | 7

Chapter
2
D9 800 & 801 Series Service Instructions
Topics:
• D9 800 & 801 Series Seal Kit
Installation

D9 800 & 801 Series Seal Kit Installation
1. To aid in reassembly of the motor, make a “V” shaped set of lines from the endcover to the housing using either
paint or a marker. With the shaft facing down, secure the motor in a vise by clamping on the housing flange (10).
2. Loosen and remove nine bolts (22) holding the motor assembly together. Place an 11/64 x 2 ½” pin through the
endcover (21) drain port and into the manifold. Remove the endcover assembly.
Note: If the pin is not used, the internal components of the endcover will fall out.
3. Flip the endcover assembly over. Remove the 11/64 x 2 ½” pin from the endcover (21) drain port. Remove the
manifold (16), pin (17), commutator (18), piston (19) and springs (20) from the endcover. Place the piston (19) on
a flat clean surface with piston seals (8 & 9) facing up. Remove the piston seals from the piston (19) and discard.
4. Remove driver (15), rotor set (14) and wear plate (13) from the motor. Remove all seals from components and
discard. Remove seal (1) from housing and discard. Remove drive link (11) and spacer ring (12) from housing.
Note: Do not allow rolls to drop from rotor assembly when removing rotor assembly from motor.
5. To aid in the reassembly of the shaft sub-assembly make a “V” shaped set of line across the rear of the housing
and the bearing locking nut on the shaft assembly using either paint or a marker. Remove the housing (10) from
the vise and flip over.
6. Remove any shaft hardware, using a press, press the shaft assembly (10a) out of the rear of the housing (10).
Remove the seal carrier insert (3). Remove the dust seal (2), o-ring seal (4), backup shim (5), and quad seal (6)
and discard all seals.
Note: At this point all parts should be cleaned in an oil-based solvent and dried using compressed air (for safety,
observe OSHA safety guidelines). All new seals should be lightly coated in clean oil prior to installation.
7. Place new dust seal (2) into seal carrier insert (3) with the lip facing up. Place new o-ring seal (4) into outer
groove of the seal carrier insert (3). Insert back up shim (5) then quad seal (6) into seal carrier insert (3). With dust
seal (2) facing down, press seal carrier insert into housing bottom bore. Press the shaft assembly (10a) into
housing (10) lining up the “V” set of lines on the bottom of the housing and shaft assembly.
8. Insert drive link (11) into shaft assembly (10a) and place bearing spacer (12) into housing (10).
Note: If a "V" shaped set of lines was drawn on the motor prior to disassembly, use them as a guide for
reassembly to insure proper positioning of components.
9. Install the housing seal (1) in the groove on the housing (10).
10. Install the wear plate (13) with the counter bore towards the housing (10).
11. Place body seals (7) in grooves in both sides of rotor set (14). Place rotor set (14) onto wear plate (13) with I.D.
spline chamfer facing wear plate. See below for rotor assembly timing.
Figure 1: D9 Rotor Assembly Timing Position
Orbital Motors | D9 800 & 801 Series Service Instructions | 10

12. Place the endcover (21) on a flat clean surface with cavity facing up. Place four springs (20) into holes in the
bottom of the cavity.
13. Install the O.D. and I.D. piston seals (8 & 9) onto the piston (19). The seals are cone shaped. The I.D. of the outer
seal and the O.D. of the inner seal should be installed towards the piston. The opposite edges should be coming
out away from the piston. See below for proper installation of the piston seals.
Figure 2: D9 Piston Seal Orientation
14. Install the piston (19) into the endcover (21). The two alignment pins in the piston (19) should be inserted into the
two holes in the bottom of the endcover (21).
15. Install the commutator (18) into the endcover (21) with the I.D. splines facing up. The commutator must be timed
correctly. There are two notches on the O.D. of the commutator (18). One of the notches is aligned with a pin
closer to the I.D. of the commutator. This notch is to be aligned with the small, drilled hole on the I.D. land of the
endcover (21). See below for timing the commutator correctly.
1
23
7
23
45 6 45 6
Figure 3: D9 Commutator Timing
a. D9 800 series motor rotation as viewed from shaft end
b. Inlet pressure
c. Return line
d. Pin
e. Commutator notch 1
f. Commutator notch 2
g. D9 801 series motor rotation as viewed from shaft end
16. Install the manifold dowel pin (17) into the endcover. Install the manifold (16) into the endcover with the large
openings facing up and the slot on the O.D. aligned with the dowel pin (17).
17. Install a 11/64 x 2 ½” pin (or similar) into the drain port of the endcover (21) and into the manifold (16)
Note: If the pin is not used, the internal components of the endcover will fall out. The endcover contents may need
to be compressed to be able to insert the pin (or similar) through the drain port and into the manifold.
Orbital Motors | D9 800 & 801 Series Service Instructions | 11

18. Install the driver (15) into the rotor set (14). Place the endcover (21) onto the rotor set (14) aligning the driver (15)
into the commutator (18).
Caution: Make sure to visually align bolt holes before the driver is in the commutator. If the commutator
spins during installation, the motor will run in the reverse direction.
19. Install nine assembly bolts (22) into endcover and pre-torque to 13.6 Nm [10 ft. lb.]. Final torque all bolts to 69.8
± 7.5 Nm [51.5 ± 5.5 ft. lb.].

Chapter
3
D9 800 & 801 Series Parts Listing
Topics:
• D9 800 & 801 Series
Replacement Kits

D9 800 & 801 Series Replacement Kits
Available Parts Kits
Note: Refer to D9 Exploded View for item numbers.
Table 1: Seal Kit(s)
Description Exploded View Item
Number
Qty. In Kit Order Number
Housing seal 1 1 800888200 (Includes item
numbers 1-9)
Dust seal 2 1
Seal carrier insert 3 1
O-ring seal 4 1
Backup shim 5 1
Quad seal 6 1
Body seal 7 2
Large piston seal 8 1
Small piston seal 9 1
Table 2: Miscellaneous Kit(s)
Description Exploded View Item
Number
Qty. In Kit Order Number
Spacer ring 12 1 800018012
Wear plate 13 1 800012000
Driver 15 1 800014000
Manifold 16 1 800015000
Manifold pin 17 1 800018009
Commutator 18 1 800012001
Endcover piston 19 1 800018004
Piston spring 20 4 800018007
2000 PSI relief valve Not shown 1 800018039
2500 PSI relief valve Not shown 1 800018047
3000 PSI relief valve Not shown 1 800018028
Table 3: Rotorset, Drive link and Bolt Kit(s)
Exploded View
Item Number
14 14 11 22
Displacement Standard Rotor
Kit
Freeturn Rotor Kit Drive Link Kit Bolt Set Kit (7)
260 800000260 800001260 800014013 800885260
Orbital Motors | D9 800 & 801 Series Parts Listing | 14

Exploded View
Item Number
14 14 11 22
Displacement Standard Rotor
Kit
Freeturn Rotor Kit Drive Link Kit Bolt Set Kit (7)
300 800000300 800001300 800014014 800885300
375 800000375 800001375 800014015 800885375
450 800000450 800001450 800014016 800885450
525 800000525 800001525 800014017 800885525
625 800000625 800001625 800014018 800885625
735 800000735 800001735 800014019 800885735
910 800000910 800001910 800014020 800885910
1K0 8000001K0 8000011K0 800014021 8008851K0
Table 4: Housing/Shaft and Related Component Kit(s)
Exploded View
Item Number
10/10a 18 Not Shown Not Shown Not Shown
Description Housing/Shaft
Kit
Key Kit Nut Kit Bolt Kit Washer Kit
C8 Housing/40
Shaft
800130101 700669105 N/A 700669305 700669306
C8 Housing/33
Shaft
800130102 N/A N/A N/A N/A
C8 Housing/41
Shaft
800130103 700669102 N/A N/A N/A
C8 Housing/42
Shaft
800130105 N/A N/A N/A N/A
C8 Housing/36
Shaft
800130106 700669104 N/A N/A N/A
C8 Housing/30
Shaft
800130107 50072459 N/A N/A N/A
C8 Housing/23
Shaft
800130109 N/A N/A N/A N/A
C8 Housing/32
Shaft
800130115 700669106 N/A N/A N/A
E8 Housing/40
Shaft
800130401 700669105 N/A 700669305 700669306
E8 Housing/33
Shaft
800130402 N/A N/A N/A N/A
E8 Housing/41
Shaft
800130403 700669102 N/A N/A N/A
E8 Housing/42
Shaft
800130405 N/A N/A N/A N/A
Orbital Motors | D9 800 & 801 Series Parts Listing | 15

Exploded View
Item Number
10/10a 18 Not Shown Not Shown Not Shown
Description Housing/Shaft
Kit
Key Kit Nut Kit Bolt Kit Washer Kit
E8 Housing/36
Shaft
800130406 700669104 N/A N/A N/A
E8 Housing/30
Shaft
800130407 50072459 N/A N/A N/A
E8 Housing/23
Shaft
800130409 N/A N/A N/A N/A
E8 Housing/32
Shaft
800130415 700669106 N/A N/A N/A
D8 Housing/38
Shaft
800130204 800018017 800018000 N/A N/A
D8 Housing/45
Shaft
800130208 700669103 700669303 N/A N/A
D8 Housing/47
Shaft
800130210 700669105 N/A 700669305 700669306
D8 Housing/68
Shaft
800130211 700669102 N/A N/A N/A
D8 Housing/72
Shaft
800130213 800018026 800018025 N/A N/A
D8 Housing/51
Shaft
800130214 700669107 700669303 700669306 N/A
W8 Housing/38
Shaft
800130304 800018017 800018000 N/A N/A
W8 Housing/45
Shaft
800130308 700669103 700669303 N/A N/A
W8 Housing/47
Shaft
800130310 700669105 N/A 700669305 700669306
W8 Housing/68
Shaft
800130311 700669102 N/A N/A N/A
W8 Housing/72
Shaft
800130313 800018026 800018025 N/A N/A
W8 Housing/51
Shaft
800130314 700669107 700669303 700669306 N/A
Table 5: Endcover Kits (Exploded View Item Number 21)
Description Standard Endcover
Kit
Valve Cavity
Endcover Kit
Internal Drain
Endcover Kit
Valve Cavity &
Internal Drain
Endcover Kit
0 800016001 N/A N/A N/A
7 800016003 N/A N/A N/A
8 800016002 N/A N/A N/A
Orbital Motors | D9 800 & 801 Series Parts Listing | 16

Description Standard Endcover
Kit
Valve Cavity
Endcover Kit
Internal Drain
Endcover Kit
Valve Cavity &
Internal Drain
Endcover Kit
9 800016000 800016004 N/A N/A
Orbital Motors | D9 800 & 801 Series Parts Listing | 17