White RE 540 Series Setup guide
Repair Instructions
RE 540/541 Series
Contents
Chapter 1: RE 540/541 Series Diagram.................................................................. 5
Exploded View......................................................................................................................................................6
Chapter 2: RE 540/541 Series Service Instructions............................................... 9
Motor Section Disassembly.................................................................................................................................10
Direct Drive Option Disassembly........................................................................................................... 10
Locking Hub Option Disassembly.......................................................................................................... 10
Motor Section General Disassembly.......................................................................................................10
Housing/Shaft with Seal Carrier Disassembly & Assembly...............................................................................11
Housing/Shaft without Seal Carrier Disassembly & Assembly..........................................................................12
Motor Section Assembly.....................................................................................................................................13
Motor Section General Assembly .......................................................................................................... 13
Direct Drive Option Assembly................................................................................................................13
Locking Hub Option Assembly...............................................................................................................14
Chapter 3: RE 540/541 Series Parts Listing......................................................... 15
Replacement Kits................................................................................................................................................ 16
Orbital Motors | Contents | iii
RE 540/541 Exploded View
Exploded View
8
9
10
27
28
30
31
32
33
35
34
29
21
22
26
12
21
7
5
6
9
44
43
42
41
D
37
36
38 39 40
C
1
14
15
16
13
17
18
19
20
23
25
45
24
17
A
1
14
15
16
13
17
18
19
20
23
25
2
4
3
11
45
24
17
B
Table 1: Options
Description Option Letter
Design without seal carrier A
Seal carrier design B
Direct drive option C
Locking hub option D
Components List
Description Item Number Description Item Number
Flange seal 1 Mounting nut 24
Orbital Motors | RE 540/541 Series Diagram | 6
Description Item Number Description Item Number
Wire ring 2 Housing 25
Metal backup shim 3 Shaft 26
High pressure seal 4 Drive link 27
Metal backup shim 5 Manifold 28
Backup seal 6 Drive link spacer 29
Shaft seal 7 Rotor assembly 30
Housing seal 8 Balance plate 31
Body seal 9 Steel ball 32
Endcover seal 10 Endcover 33
Seal carrier 11 ID tag assembly 34
Thrust washer 12 Assembly bolt 35
Stud 13 Driver cover screw 36
Lug nut 14 Driver cover 37
Capscrew 15 Paper gasket 38
Wheel flange 16 Driver 39
125mm bearing 17 Spacer 40
Bearing spacer 18 Screw 41
Thrust ring 19 Locking hub 42
Bearing hub 20 Wire ring 43
Thrust bearing 21 Locking hub spline
assembly
44
Rear housing bearing 22 Motor/Hub seal 46
Planetary mount stud 23
Note: The motor design that utilizes a seal carrier will use the larger O.D. backup seal and shaft seal.
Orbital Motors | RE 540/541 Series Diagram | 7
Chapter
2
RE 540/541 Series Service Instructions
Topics:
•
RE 540/541 Motor Section
Disassembly
•
RE 540/541 Housing/Shaft with
Seal Carrier Disassembly &
Assembly
•
RE 540/541 Housing/Shaft
Assembly without Seal Carrier
Disassembly & Assembly
•
RE 540/541 Motor Section
Assembly
dimensions: mm [in]
Note: In December 2006, the 540 series incorporated a design change. This
set of instructions will aid in the disassembly and assembly for both designs.
Please refer to the exploded view drawing to determine which design is being
repaired and follow the appropriate instructions for that design.
The 540 Series is available with either a direct drive option or a locking hub
option. After determining which option you have, use the appropriate
instruction.
All internal seals on products manufactured after July 1, 2016 are o-ring seals.
Prior to this date the internal seals were square cut seals. It is recommended
that if the product being serviced has square seals to replace with the square
seals in this kit, likewise if the product has o-ring seals, replace with the o-
ring seals in this kit.
RE 540/541 Motor Section Disassembly
RE 540/541 Direct Drive Option Disassembly
Uses items 36-40
Remove six bolts (36) from end cap (37).
a) Lift end cap (37) off wheel flange (16).
b) Peel or scrape paper gasket (38) off of end cap and/or wheel flange (16).
c) If grease is between end cap (37) and driver (39), remove grease.
d) Screw a 1/4-20 bolt (NOT INCLUDED) into one of the two threaded holes in the driver (39) and lift the driver
out of the wheel flange (16).
e) If grease is between driver (39) and housing pilot (25), remove grease.
f) If spacer (40) did not come out with driver (39), remove it at this time and lay aside.
RE 540/541 Locking Hub Option Disassembly
USES ITEMS 41-44
Remove six screws (41) from locking hub (42).
a) Lift locking hub (42) off of wheel flange (16).
b) Remove wire ring (43).
c) Install two screws (41) in opposite holes in the locking hub splined assembly (44) and use to lift locking hub
spline assembly (44) out of wheel flange (16).
d) If grease is between locking hub spline assembly (44) and housing (25) pilot, remove grease.
e) Lay parts aside.
Note: The two bearings (17) are Loc-Tited to bearing hub (20), wheel flange (16) and housing pilot (25). The four
capscrews (15) are also Loc-Tited. It is not necessary to remove these components to install this seal kit in the
motor. Unless the bearings are damaged, it is not recommend to disassemble of these components. If damage has
occurred to the bearings, it is recommended to return the unit to the factory for service, however dust seal (45) is
included in this kit in the event the bearing hub is disassembled despite the recommendation listed above.
RE 540/541 Motor Section General Disassembly
Same Instructions For Both Designs & Drive Options
1. To aid in reassembly of motor, make a "V" shaped set of lines from the endcover (33) to the housing (25) using
either paint or a marker.
a) With shaft end facing down, secure motor in vise by clamping on to the housing (25).
b) Loosen and remove seven bolts (35) holding motor assembly together.
c) Remove end cover (33) and endcover seal (10).
d) Discard seal.
2. Remove balance plate (31) taking care not to drop the three steel balls (32) located in the three holes in the
balance plate (31).
a) Remove rotor assembly (30), manifold (28), drive link spacer (29), drive link (27) and thrust bearing (21).
Note: Some motors do not use spacer.
b) Remove body seals (9) from rotor assembly (30) and housing seal (8) from housing (25) and discard seals.
c) Remove shaft (26) up through the housing.
Orbital Motors | RE 540/541 Series Service Instructions | 10
RE 540/541 Housing/Shaft with Seal Carrier Disassembly & Assembly
Design That Utilizes A Seal Carrier (11)
1. Remove housing (25) from vise and place on a clean flat surface with hub end facing up.
a) Using shaft (26) and rubber mallet, tap seal carrier (11) down to expose wire ring (2).
b) Remove wire ring (2), steel backup shim (3) and high pressure seal (4) from inner bore groove with a long
narrow screwdriver.
c) Lift the seal carrier (11), thrust washer (12) and thrust bearing (21) from the housing bore.
d) Using a small screwdriver, carefully pry shaft seal (7), backup seal (6), and metal backup shim (5) from seal
carrier (11) and discard.
e) Lay seal carrier (11), thrust washer (12) and thrust bearing (21) aside.
Note: If a new thrust washer (12) and seal carrier (11) is included in kit, old items may be discarded.
Note: At this point, all parts should be cleaned in an oil-based solvent and dried using compressed air (for safety,
observe all OSHA safety guidelines). All new seals should be lightly coated in clean oil prior to installation.
2. Place shaft (26) on a clean surface with output end facing up.
a) Place thrust bearing (21) over shaft (26) and then place thrust washer (12) over shaft (26).
b) After thoroughly coating shaft seal (7) and backup seal (6) with clean oil, place plastic installation sleeve down
over shaft making sure to cover all splines, keyways, etc.
c) Making sure lip on shaft seal (7) faces down, push shaft seal down plastic installation sleeve until it contacts
thrust washer (12).
d) Remove installation sleeve.
e) Install backup seal (6) making sure that lip faces shaft seal (See Figure 1: Figure 1 on page 11 for correct
seal positions).
f) Install metal backup shim (5) down against backup seal (6).
g) Place seal carrier (11) onto shaft with large end facing down.
h) Using an arbor press, carefully press seal carrier down to seat shaft seal (7) in carrier.
1 3
2 4
5
6
7
1Wire ring
2Backup shim
3High pressure seal
4Seal carrier
5Backup shim
6Backup seal
7Shaft seal
Figure 1: Figure 1
3. Place hub/housing assembly on a clean flat surface with hub end facing up.
a) Due to planetary mounting studs (23), a spacer should be placed under housing (25) to prevent shaft (26) from
dropping to work surface.
Orbital Motors | RE 540/541 Series Service Instructions | 11
b) Spacer should allow shaft to be about 13 [.50] below rear surface of housing.
c) Place shaft (26) assembly into housing (25).
d) Install high pressure seal (4) in seal groove in housing pilot (25).
e) Install metal backup shim (3) against high pressure seal (4) by squeezing the shim (3) between thumb and
forefinger to bow shim.
f) While maintaining bow in shim, start the shim into the groove and use a small screwdriver to push the shim
into groove.
g) Install wire ring (2) into groove making sure that the ends are butted.
4. Turn hub/housing assembly over, with hub facing down, and place drive link (27) into shaft (26) making sure that
end of drive link with crowned splines goes into shaft (26).
a) Using an arbor press, carefully press the shaft down to seat seal carrier against wire ring (2) install thrust
bearing (21) onto end of shaft.
b) If all pieces are seated properly, thrust bearing (21) will be flush with rear face of housing (25).
RE 540/541 Housing/Shaft Assembly without Seal Carrier
Disassembly & Assembly
Design That Does NOT Utilizes A Seal Carrier (11)
1. Position the housing (25) in vise and use a slide and hammer type bearing puller to remove the rear housing
bearing (22).
a) Remove the thrust washer (12) and thrust bearing (21) and set aside.
b) Using a small screwdriver carefully pry the shaft seal (7), backup seal (6) and metal shim (5) from housing
bore and discard.
2. Remove the housing from vise and turn over and pry the dust seal (1) from housing and discard.
Note: At this point, all parts should be cleaned in an oil-based solvent and dried using compressed air (for safety,
observe all OSHA safety guidelines). All new seals should be lightly coated in clean oil prior to installation.
3. Place housing (25) in vice with the seven bolt assembly holes facing up.
a) Place metal shim (5) in the smallest diameter recess in the housing (25).
b) Install the backup seal (6) into the housing (25) with the flat side down and the seal lip facing up.
c) Insert shaft seal (7) down into housing (25) making sure that lip on seal faces up (See Figure 2: Figure 2 on
page 12 for correct seal orientation).
d) Install thrust washer (12) into housing and using an arbor press, seat the shaft seal (7) into housing (25), then
place the thrust bearing (21) into housing.
1
2
3
4
1Housing
2Metal backup shim
3Backup seal
4Shaft seal
Figure 2: Figure 2
Orbital Motors | RE 540/541 Series Service Instructions | 12
4. Place the rear housing bearing (22) onto the rear housing bore and press to a depth of 58.4 [2.3] from the rear
surface of the housing (25) to the top of the bearing (22).
a) Place the shaft (26) down into housing (25) and place thrust bearing (21) on top of shaft (26).
b) If shaft seals are properly seated against the housing (25), thrust bearing (21) will be flush with rear surface of
housing.
RE 540/541 Motor Section Assembly
RE 540/541 Motor Section General Assembly
Same Instructions For Both Designs & Drive Options
1. Install housing seal (8) into groove in housing (25). Place manifold (28) onto housing (25) aligning bolt holes.
Note: Manifold side with only seven valving hole goes toward housing.
2. Install a body seal (9) into the seal groove in both sides of rotor assembly (30).
a) Place rotor assembly (30) on manifold with side of rotor with chamfer in splines facing manifold (28).
b) Turn rotor assembly (30) to align bolt holes and alignment marks.
3. If motor came with spacer (29), place spacer (29) on end of drive link (27).
a) Using alignment marks as a guide, place balance plate (31) onto the rotor assembly (30) with three holes for
steel balls (32) facing up.
b) Install three steel balls (32) into the holes in the balance plate (31).
4. Install endcover seal (10) into groove in endcover (33).
a) Place endcover (33) onto the balance plate (31) and align bolt holes.
b) Insert seven bolts (35) into motor assembly.
Pre-torque bolts to 13.6 Nm [10 ft. lb.].
c) Using the bolt torque pattern in Figure 3: Figure 3 on page 13, final torque all bolts to 69.8 ± 7.5 Nm [51.5 ±
5.5 ft. lb.].
1
2
4
5
6
3
7
Figure 3: Figure 3
5. Turn motor over with hub end facing up. Reapply grease in housing pilot.
RE 540/541 Direct Drive Option Assembly
USES ITEMS 36-40
Place spacer (40) over shaft (26).
a) Place driver (39) over shaft (26) while rotating wheel flange (16) slightly to allow splines to mate.
b) Place paper gasket (38) onto wheel flange (16).
c) Reapply grease between driver (39) and end cap (37) (Only if end cap (37) does not have grease fitting).
d) Place end cap (37) onto wheel flange (16).
e) Install six bolts (36) and torque to 69.8 ± 7.5 Nm [51.5 ± 5.5 ft. lb.] using the bolt torque sequence shown in
Figure 4: Figure 4 on page 14.
f) If end cap (37) has grease fitting, apply grease.
Orbital Motors | RE 540/541 Series Service Instructions | 13
1
2
3
4 5
6
Figure 4: Figure 4
RE 540/541 Locking Hub Option Assembly
USES ITEMS 41-44
Place locking hub spline assembly (44) into wheel flange (16) while rotating wheel flange (16) slightly to allow
splines to mate.
a) Install wire ring (43).
b) Align screw holes of locking hub (42) with screw holes in locking hub spline assembly (44) and gently press
together
c) Install six screws (41) into locking hub (42) and torque to 3.3 ± 0.2 Nm [29 ± 2 in. lb.].
RE 540/541 Replacement Kits
Available Kits
Note: Refer to the Exploded View on page 6 for item numbers.
Table 2: Seal kits
Description Exploded View Item
Number
Qty. In Kit Order Number
Flange seal 1 1 500444125 (Includes item
numbers 1-10 & 38)
Wire ring 2 1
Metal backup shim 3 1
High pressure seal 4 1
Metal backup shim 5 1
Backup seal 6 2
Shaft seal 7 2
Rear housing seal 8 1
Body seal 9 1
Endcover seal 10 1
Paper gasket 38 1
Seal carrier 11 1 500444003(Includes item
numbers 11 & 12)
Thrust washer 12
Table 3: Micellaneous kits
Description Exploded View Item
Number
Qty. In Kit Order Number
Stud 13 1 500018081
Lug nut 14 1 500018151
Capscrew 15 4 500018086
Wheel flange 16 1 500013035
125mm bearing 17 1 500018095
Bearing spacer 18 1 500018194
Thrust ring 19 1 500018062
Bearing hub 20 1 500013055
Thrust bearing 21 1 500018059
Rear housing bearing 22 1 500018002
Planetary mount stud 23 1 500018081
Mounting nut 24 1 500018112
Orbital Motors | RE 540/541 Series Parts Listing | 16
Description Exploded View Item
Number
Qty. In Kit Order Number
Forward manifold (CCW
or "0")
28 1 500015006
Reverse manifold (CW or
"1")
28 1 500015007
Balance plate (3 balls
included)
31 & 32 1 500012001
Steel ball 32 3 500018048
Endcover 33 1 500016001
Driver cover screw 36 6 500018085
Driver cover 37 1 700018001
Driver 39 1 500018179
Spacer 40 1 500018114
Warn hub assembly 41-44 1 500018099
Rotors, drive links and spacers, and bolts
When changing motor displacements, a matching rotor and bolt set kit must be ordered. A new drive link kit may be
necessary. Dive link spacers are included in drive link kits, but may also be ordered separately by using the drive link
spacer kit number.
Exploded View
Item Number
30 30 27 29 35
Displacement Standard Rotor
Kit
Freeturn Rotor
Kit
Drive Link Kit Drive Link
Spacer kit
Bolt Set Kit
120 500087005 500087008 500014009 - 500445006
160 500137005 500137011 500014009 - 500445006
200 500167004 500167011 500014009 500018075 500445012
230 500147002 500147004 500014009 500018185 500445014
260 500227000 500227004 500014039 - 500445014
300 500247005 500247011 500014007 - 500445018
350 500207000 500207004 500014042 - 500445026
375 500307005 500307011 500014008 - 500445024
470 500357003 500357005 500014042 - 500445026
540 500407005 500407011 500014044 - 500445032
750 500607005 500607011 500014047 - 500445045
Housing kits
Exploded view item #25
Standard housing kits include rear housing bearing(#22) installed in the housing.
Orbital Motors | RE 540/541 Series Parts Listing | 17
Description Order Number
#W31- setback with 7/8" o-ring 500131023
Internal shaft
Exploded view item #26
Description Shaft Kit
#24- 19 Tooth spline 500011102
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