Ser. Man. SD-96101 - Industrial Global Sales
Contents
1. Haldex W Series Hydraulic Gear Pump amp Gear Motor Inspection Servicing u a Service Manual August 1996 Revised June 1998 W Series Gear Pump Retaining ring Shaft Seal pone Flange Backup Ring E Seal Z d e Rearing block O Ring wer Dowel Pin ses O a Single Pump 900 Series Shown Idler Gear Drive Gear l End Cover d om as required Bolt metric Coupling D x Ke E Plate W of 52 O e I u Double Pump aA N 900 Series Shown 4 On KC Dar 5y Barnes Hydraulics Tools Required e Metric Socket Set e Internal Snap Ring Pliers e Shaft Seal Sleeve e Torque Wrench 100 lb ft capacity Disassembly Note The following general instructions also apply to multiple section gear pumps the only extra parts are the coupling between the drive shafts and the center distance plate which divides the two pump sections This repair procedure also applies to the W series Gear Motors 1 Itis very important to work in a clean work area when repairing hydraulic products Plug ports and wash exte rior of pump with a proper cleaning solvent before con tinuing 2 Remove port plugs and drain oil from pump 3 Use a permanent marker pen to mark a line across the mounting flange gear housing and end cover This will assure proper reassembly and rotation of pump 4 Remove key from drive shaft if applicable W Series Gear Pu2. Insert the drive end of the drive shaft through the bear ing block with the seal side down and the open side of the E seal pointing to the intake side of the pump 8 Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal Remove the seal sleeve from shaft 9 Install the idler gear shaft in the remaining position in the bearing block Apply a light coat of clean oil to the face of the drive and idler gears 10 Pick up the rear bearing block with seal side up and with open end of the E seal facing the intake side of the pump place over the drive and idler gear shafts 11 Install two dowel pins in the holes in the mounting flange or two long dowel pins through gear housing if pump is a multiple section pump 12 To install the o rings in the gear housing apply a light coating of petroleum jelly in the grooves on both sides of the gear housing Also coat the new o rings and install them in the grooves Choose correct size o ring refer to instructions on page 9 Barnes Hydraulics 13 Gently slide the gear housing over the rear bearing block assembly slide housing down until the housing en gages the dowel pins Press firmly in place with hands do not force or use any tool Check to make sure the intake port in the housing is on the same side as the open end of the E seal and that the marked lines on the mount ing flange and gear housing are in alignment 14 The
3. position Reassembly Note New seals should be installed upon reassem bly of pump or motor Refer to page 8 for the neces sary kit part numbers for the W 600 W 900 and W 1500 pumps and motors 1 Install new shaft seal in mounting flange with part number side facing outboard Press the seal into the seal bore until the seal reaches the bottom of the bore Uni form pressure must be used to prevent misalignment or damage to the seal 2 Install retaining ring in groove in seal bore of mounting flange 3 Place front and back bearing blocks on a clean sur face with the E seal grooves facing up Apply a light coat W Series Gear Pump ing of petroleum jelly in the grooves Also coat the E seal and backup with the petroleum jelly this will help keep the seals in place during reassembly 4 Place the E seals flat side outward into the grooves in both bearing blocks Follow by carefully placing the backup ring flat side outward in the groove made by the E seal and the groove in the bearing block Note In the W900 series pump in the center of the backup ring and E seal there is a notch make sure that these notches line up so the backup ring will set flush with the E seal The backup ring in the W1500 pump is sym metrical 5 Place mounting flange with shaft seal side down ona clean flat surface 6 Apply a light coating of petroleum jelly to the exposed face of the front bearing block bie 7
4. surface of the rear bearing block should be slightly below the face of the gear housing If the bearing block sits higher then the rear face of the gear housing then the E seal or o ring have shifted out of the groove If this is the case remove the gear housing and check for proper seal installation 15 Install the two remaining dowel pins in the rear of the gear housing if applicable and place the end cover over the back of the pump 16 Install the four spacers if applicable and hex head bolts through the bolt holes in the end cover hand tighten W Series Gear Pump u 17 Place mounting flange of the pump back in the pro tected jawed vise and alternately torque the bolts to the torque specifications in the torque chart on page 8 All torque figures are for dry torque bolts 18 Remove pump from vise 19 Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution If the drive shaft binds disassemble the pump and check for assembly problems then reassemble the pump 20 The name plate located on the end cover contains the build date code and the model number Please refer to this information when corresponding with the Haldex Barnes Service Department Date Code Identification 3 4 98 e Month Year Week of Month W Series Gear Pump Placing Pump Back Into Service 1 If shop test stand is available the followin
5. 122 3 40 3 60mm 134 142 A GROOVE Nut 1 24 1 40mm 049 055 1 70 1 85mm 4 057 073 O RING CROSS SECT O Ringe Schnitt O RING GROOVE O Ring Nut GEAR HOUSING Pumpengehause GROOVE Nut 88 2 03mm 074 080 2 54 2 ove 100 10 O RING CROSS SECT O Ringe Schnitt W Series Gear Pump NOTES 10 W Series Gear Pump NOTES 11 W Series Gear Pump AUTHORIZED DISTRIBUTOR Barnes Hydraulics 2222 15TH STREET 214 JAMES FARM RoAD POSTFACH 1507 95014 HOF RINGVAGEN 3 Box 95 Rockroro IL 61104 USA STATESVILLE NC 28677 USA SELIGENWEG 12 95028 HOF S 280 40 SKANES FAGERHULT PHONE 815 398 4400 PHONE 704 873 2587 GERMANY SWEDEN Fax SERVICE DEPT 815 398 9817 FAX SERVICE DEPT 704 838 7987 PHONE 49 9281 8950 PHONE 46 433 302 90 Fax SALES DEPT 815 398 597 7 Fax 49 9281 87133 Fax 46 433 305 46 Form No SD 96101 Copyright Haldex Barnes Hydraulics 1996 Revised June 1998 All Rights Reserved Printed in USA
6. 76 Lb in 19 23 Ib ft 25 8 31 2 N m W 900 METRIC 10 x 1 5 600 660 Ib in 50 55 Ib ft 68 75 N m 456 516 Ib in 38 43 lb ft 51 5 58 3 N m W 1500 METRIC 12 x 1 75 960 1020 Ib in 80 85 Ib ft 108 115 N m 816 876 Ib in 68 73 Ib ft 92 2 99 0 N m Bolts and flange threaded hole must be in dry non lubricated condition Single or Double Pump Trouble Shooting PUMP TROUBLE PROBABLE CAUSE REMEDY 1 Pump does not develop full pressure 2 Pump will not pump oil 3 Noisy pump caused by cavitation 4 Oil heating 5 Foaming oil 6 Shaft seal leakage a System relief valve set too low or leaking b Oil viscosity too low oil too thin c Pump is worn out d Seal Retainer O ring pinched a Reservoir low or empty b Suction strainer clogged c Incorrect shaft rotation a Oil too thick b Oil suction filter plugged c Suction line plugged or too small a Oil supply low b Contaminated oil c Setting of relief valve too high or too low d Oil viscosity too low a Low oil level b Air leaking into suction line c Wrong kind of oil a Worn shaft seal or cut seal lip b Worn shaft in seal area c Wrong pump shaft rotation a Check system relief valve for proper setting b Change to proper viscosity oil c Repair or replace pump d Disassemble pump and check o ring a Fill reservoir to proper level b Clean suction strainer c Check for proper rotation of pump shaft
7. a Change to proper viscosity b Clean filters c Clean line and check for proper size a Fill reservoir to proper level b Drain reservoir and refill with clean oil c Set to correct pressure d Drain reservoir and fill with proper viscosity a Fill reservoir to proper level b Tighten fittings check condition of line c Drain reservoir fill with non foaming oil a Replace shaft seal b Replace drive shaft and seal c Check for proper rotation of pump shaft Barnes Hydraulics W Series Gear Pump Pump Motor Seal Kit Chart W 600 SERIES W 900 SERIES W 1500 SERIES W 1500 SERIES KIT 5400042 5000100 5200001 5200015 5400044 5000101 5200002 5200016 NOTE 1500 Series Pumps manufactured from late 1996 use 35mm O D shaft seals 1500 Series Motors are not affected Effective June 1998 kits servicing the W 900 Series Pumps will contain two different size o rings for between housing and end plates refer to drawing below for instructions IMPORTANT NOTICE THIS KIT CONTAINS O RINGS OF TWO SIZES Wichtiger Hinweis Dieser Dichtsatz enthoelt O Ringe in zwei verschiedenen Groessen zur Abdichtung der Pumpengehaeuse Dos Pumpengehaeuse hat zwei identische O Ring Nuten Ermitteln Sie die Nutabmessungen siehe Abbildungen um den passenden O Ring auszuwaehlen Abbildung nicht masstaeblich INDICATED BELOW TO DETERMINE APPROPRIATE O RING SIZES TO BE USED VIEWS ARE NOT ACTUAL SIZE 3 00 3 10mm 118
8. g procedure for testing rebuilt pumps is recommended A Mount pump on test stand making sure that the proper level of clean oil is available in the reservoir Check suction line for leaks and obstructions B Start pump and run for three minutes at zero pressure C Intermittently load pump to 500 P S I for three minutes D Intermittently load pump to 1000 P S I for three minutes E Intermittently load pump to 2000 P S I for three minutes F Remove pump from test stand and check for freeness of drive shaft Check pump for signs of external leakage 2 If shop test stand is not available the following proce dure for testing rebuilt pumps is recommended A For engine driven pumps mount pump on equipment and run pump at 1 2 engine speed at zero pressure for three minutes B By operating control valve build pressure intermittently for three minutes C Increase engine speed to full throttle and build pressure intermittently for three minutes D Stop engine and check pump for external leaks E For electric motor driven pumps run pump at little or no load for three minutes gradually increase load on pump and cycle each succeeding load for three minutes Check pump for external leaks after break in test Bolt Torque Chart PUMP SERIES THREAD SIZE TORQUE VALUES BLACK OXIDE TORQUE VALUES BLACK OXIDE BLACK OXIDE TORQUE VALUES ZINC PLATE TORQUE VALUES ZINC PLATE ZINC PLATE W 600 METRIC 8 x 1 25 228 2
9. ints and seal area for rough surfaces and excessive wear Check gear face Check edge of gear teeth 4 Inspect gear face for scoring or excessive wear If the face edge of gear teeth are sharp they will mill into the bearing blocks If wear has occurred the parts are unus able Check face Block thickness must equal no gear wear 5 Inspect bearing blocks for excessive wear or scoring on the surfaces which are in contact with the gears Also inspect the bearings for excessive wear or scoring 6 Inspect the area inside the gear housing It is normal for the surface inside the gear housing to show a clean wipe on the inside surface on the intake side There should not be excessive wear or deep scratches and gouges General Information It is important that the relationship of the mounting flange bearing blocks and gear housing is correct Failure to prop erly assemble this pump will result with little or no flow at rated pressure Reverse Shaft Rotation of Pump Note This pump is not bi rotational if the shaft ro tation must be changed the following procedure must be followed Reversing the shaft rotation of the W se ries gear pump may be accomplished by rotating as a group the two bearing blocks and the gear housing 180 in relationship to the remaining parts of the pump This W Series Gear Pump procedure will place the pressure port on the opposite side of the pump from its original
10. mp 6 Loosen the four metric hex head bolts 7 Remove pump from vise and place on clean work bench remove the four hex head bolts and spacers if applicable 8 Lift and remove end cover 9 Carefully remove gear housing and place on work bench Make sure the rear bearing block remains on the drive and idler shafts 5 Clamp mounting flange in a protected jaw vise with pump shaft facing down 10 Remove rear bearing block from drive and idler shafts W Series Gear Pump 12 Remove drive shaft from mounting flange There is no need to protect the shaft seal as it will be replaced as a new item 14 Turn mounting flange over with shaft seal up and remove the retaining ring with proper snap ring pliers 15 Remove the oil seal from mounting flange be careful not to mar or scratch the seal bore 16 Remove the dowel pins from the gear housing Do not lose pins 17 Remove seals from both bearing blocks and discard Inspect Parts For Wear 1 Clean and dry all parts thoroughly prior to inspection It is not necessary to inspect the seals as they will be replaced as new items Check these points 2 Check drive shaft spline for twisted or broken teeth check keyed drive shaft for broken or chipped keyway No marks or grooves on shaft in seal area some discolora tion of shaft is allowable Barnes Hydraulics 3 Inspect both the drive gear shaft and idler gear shafts at the bearing po
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