General Purpose Motors2General Purpose Motors S Series Geroler MotorsTools required for disassembly and reassembly.lTorque wrench (34Nm 300 Ib-in capacity)l300-400mm 12-16 inch breaker barl5/16-12 point socket no. 5422 (Heavy Duty-56Nm 500 Ib-in capacity)l5/16 12 point socket no. 5422 (Heavy Duty-56Nm 500 Ib-in capacity)lSmall screwdriver (150-200 x 6mm 6-8 x .25 inch flat blade), see page 6 for tooling information.l3/16 inch 5mm hex keylShaft pressure seal installation tool for -008 motor P/N 600470lShaft pressure seal installation tool for -009 and -010 motors P/N 600523lSeal sleeve or bullet P/N 600304 (1 inch dia. shaft), P/N 600466The following tools are not necessary for disassembly and reassembly but are extremely helpful.lSmall propane torch*Tools available-by special order-through our service department. 3General Purpose MotorsCleanliness 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.S Series Disassembly3 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).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.Figure 14Figure 3Figure 2General Purpose Motors5S Series Disassembly9 Remove spacer plate 10 Remove drive, see Fig. 4. 11 Remove seal from housing.14 Remove motor from vise. Place on clean flat surface. Carefully lift flange from housing with a twisting motion.The screws will require approximately 34-45Nm 300-400 Ib-in of torque to break loose and approximately 11 Nm 100 Ib-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 instruction. 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.Figure 6Figure 5Clamp across portsnot across housing. Excessive clamping pressure causes distorsion.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.Figure 4General Purpose MotorsS Series Disassembly15 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.Figure 7Figure 8Figure 10Figure 916 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.6General Purpose Motors S Series Reassembly19 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