6000 Series (includes Big 6)

Char-Lynn Geroler® Motors

Disc valve motor -006

Repair information
6000 Series Char-Lynn Motors

Cross section drawing

Char-Lynn® 6000 Series motor bearing package change

Current production -006 Version

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 6000 Series Char-Lynn Motors

Parts drawing

Seal Geroler

Shuttle (Two way)

Plug Assembly Spring

Geroler Seal Poppet

Spring Plug Assembly
Plug assembly
Sleeve, Dash Pot Seal
Check Piston Shuttle Plug
valve
plug Outer Valve housing
Seal Sleeve, Dash Pot
assembly face (Split flange ports)
Inner seal Balance
face ring
seal

Bolt Spring Valve

Valve Valve
plate drive
Seal
Shaft and
Geroler
Spring Housing, Bearing bearing kit
Drive (1-1/2 inch
Ball
17 tooth splined)

Shaft and
Valve housing bearing kit
(1-1/2 inch straight)
Shuttle valve
Key
location when
applicable
Seal
Plug Seal
Seal
assembly
Seal

Bearingless Seal
motor mounting
flange Shaft seal
Shaft face seal
O-ring Back-up
ring (If
Dust Seal supplied)
Bearing Screw, Cap
Housing Retainer, Front
Wheel
Motor Dust seal
Shaft and
Bearing Kit Key
(1-3/4 in.
Tapered)
Retainer Retainer
Optional
Seal Guard

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6000 Series Char-Lynn Motors

Parts drawing — Big 6

Shaft face seal

Screw, Cap

Special global mount

Shaft and bearing

assembly Seal Shaft seal

Retainer, Front Dust seal

Tools
Wheel motor and bearingless motor repair information on page 11,12. Shuttle valve and seal
guard repair information on page 13. Seal guard reference on page 13.
Tools required for disassembly and reassembly
•• Torque wrench (90 Nm [800 lb-in] capacity)
•• 305 to 406 mm [12 to 16 inch] breaker bar
•• 3/4 inch and 1/2 inch sockets
•• Small screwdriver (150 to 200 mm [6 to 8 inch] long,
•• 6 mm [1/4 inch] blade)
•• 3/16 inch Hex Key
•• Hydraulic press — 1335 N [300 lbf]
•• Plastic or rubber hammer
•• *Bullet (600464) for 1-1/2 inch diameter shafts
*Available by special order through our service department.
Alignment studs (2)
215,9 [8.50]
(273,05 [10.75] required for 985 cm3/r [60.0 in3/r] Displ.)
Approx. 12,7 [.50] 25,4 [1.00]

12,7 [.50] Dia. Steel Rod

9,52 [.375]
1/2-20 UNF thread
Grind flat spots on each side

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 6000 Series Char-Lynn Motors

Disassembly
Cleanliness is extremely important when repairing a
hydraulic motor. Work in a clean area. Before disconnecting Plug
the lines, clean port area of motor thoroughly. Use a wire Valve
assembly
brush to remove foreign material and debris from exterior housing
joints of motor. Check shaft and keyway, use 600 grit paper/
cloth to remove all nicks, burrs, and sharp edges that might
damage the shaft seals when installing retainer on shaft and
bearing assembly. Before starting disassembly procedures,
drain oil from inside of motor.
Check plug
assembly Seal

Figure 3

4. Carefully remove the following from the valve

housing:
1 seal, 92,3 mm [3.63 inch] I.D.
1 seal, 7,6 mm [.30 inch] I.D.
2 check valve plug assemblies (plug, seal, spring,
ball) 1 plug (case drain) with seal.

Figure 1 Valve
1. Place motor in a vise with output shaft down. Clamp
across edge of bearing housing not on housing (see Spring (3)
Figure 1). Excessive clamping pressure on housing
will cause distortion. When clamping, use some Inner
protective device on vise, such as special soft jaws, face
pieces of hard rubber or board. seal Outer
Although not all drawings show the motor in a vise, face
we recommend that you keep the motor in the vise seal Balance ring
during disassembly. Follow the clamping procedures
explained throughout the manual.
2. Remove 4 bolts (or nuts for earlier models) from Figure 4
motor. Remove studs (earlier models) as shown in
step 16. 5. Remove 3 balance ring springs.
6. Remove balance ring subassembly.
7. Remove inner and outer face seals from the balance
ring.
8. Lift off valve.
Valve drive

Figure 2
Valve plate
3. Lift valve housing straight up. If done carefully, the Seal
springs and balance ring subassembly will remain on
valve for easy removal.
Figure 5

9. Remove valve plate.

10. Remove 95,0 mm [3.74 inch] I.D. seal from valve plate
(see Figure 5).
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6000 Series Char-Lynn Motors

Disassembly
11. Remove valve drive (see Figure 5).

Geroler Seal
Seal

Shaft
seal Retainer

Back-up
ring Dust seal

Seal Drive

Figure 9
Figure 6 17. Remove 92,3 mm [3.64 inch] I.D. seal, shaft seal and
12. Remove Geroler. Retain rollers in outer Geroler ring back-up ring (if supplied) from retainer. Use a small
if they are loose. screwdriver to remove dust seal. Do not damage
bore of retainer.
13. Remove 2 seals (6,1mm [.24 inch]) from Geroler, 1
seal on each side of Geroler.
14. Remove drive.
15. Remove 95,0 mm [3.74 inch] I.D. seal from bearing Shaft face seal
housing. Shaft and
bearing
16. Use a stud remover or vise grips to remove studs assembly
(earlier models only). Then clamp bearing housing
in vise as shown in Figure 7. Loosen 6 bolts. Then Bearing
remove bolts and retainer. You may have to pry housing
retainer free but do not damage housing or retainer.

Figure 10

18. Remove shaft and bearing assembly. You may need a

press to remove shaft and bearing assembly
(see Figure 10)
19. Remove shaft face seal from bore of bearing housing
(see Figure 10). Do not damage bore of bearing
housing.

NNote: Individual parts of the shaft and bearing assembly are

Figure 7 not sold separately and must be replaced as a unit.

Figure 8

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 6000 Series Char-Lynn Motors

Reassembly
Check all mating surfaces. Replace any parts that have 21. Install shaft and bearing assembly in bearing housing
scratches or burrs that couId cause leakage. Clean all (see Figure 12). Do not damage seal in bore of
metal parts in clean solvent. Blow dry with air. Do not housing. You may need a press to install shaft and
wipe with cloth or paper towel because lint or other bearing assembly.
matter could get into the hydraulic system and cause
damage. Do not use a coarse grit papers/cloth or try to
file or grind motor parts. Check around the keyway and Seal
chamfered area of the shaft for burrs, nicks, or sharp
edges that can damage the seals when reassembling
the retainer. Shaft
seal Retainer
NNote: Lubricate all seals (prior to installation) with
petroleum jelly such as Vaseline®. Use new seals Back-up
ring
when reassembling the motor. Refer to parts list Dust Seal
(6-159 6000 Series - 006) for replacement parts and
proper kit number.
Figure 13

22. Use a small press, if available, to install dust seal in

retainer. Metal side of dust seal must face toward
retainer as shown in Figure 14. If a press isn’t
available, use a plastic or rubber hammer to tap dust
seal in place.
Dust Seal Lip
Shaft Back-up
face ring
Bearing Shaft and
seal housing Shaft bearingless
seal assembly

Retainer
Seal
seat
Seal

Figure 11

20. Place bearing housing on smooth flat surface with

largest open end of housing up. Bearing
housing

Apply petroleum jelly to shaft face seal. Install seal in

seal seat. Seat seal properly in groove (see Figure 11 and Shaft
14). A damaged or improperly installed shaft face seal face
could cause internal lubrication loss and subsequent seal
parts wear. Figure 14

23. Install 92,3 [3.64] I.D. seal, back-up ring and shaft seal
in retainer. Flat or smooth side of shaft seal must
face toward retainer as shown in Figure 14. Apply
Bearing Shaft and petroleum jelly to inside diameter of shaft seal
housing bearing (after installing seal).
assembly
24. Before installing retainer, place a protective sleeve
of bullet (see note below) over shaft. Grease inside
diameter of dust and shaft seals. To prevent damage
to seals, install retainer over shaft with a twisting
motion. Do not cut or distort shaft seal. Damage to
shaft seal will cause external leakage.

NNote: Bullet 600464 for 1-1/2 inch diameter shafts

Figure 12 available—by special order through our service
department.

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6000 Series Char-Lynn Motors

Reassembly
1 I.D. Install seals (1 on each side of Geroler) in case
drain grooves of Geroler.
3 6
NNote: Installation at this point involves 3 steps in timing the
motor. Timing determines the direction of rotation of
the output shaft.
Timing parts include:
1. Geroler
2. Valve drive
5 4
3. Valve Plate
2
4. Valve
Figure 15

25. Lubricate threads of 6 bolts with a film of light oil. Rotate valve clockwise Anyone of 6 ports Largest open
Install and finger tighten all 6 bolts. Torque bolts to 6 1/2 tooth to engage spline open to outside pocket
Nm [50 lb-in] in sequence (see Figure 15). Then final of valve
torque to 34 Nm [300 lb-in], in sequence.

NNote: Full torque 34 Nm [300 lb-in] on one bolt at a time Geroler

can damage bolt or retainer.
Valve
Seal Valve
plate

Alignment
Ref. Only

Note: Case drain holes (2) Case drain Pressure

proper alignment shown hole relief hole
Figure 17 Timing alignment

Timing Step No. 1 — Locate largest open pocket in

Geroler. Then mark location of pocket on outside edge of
Figure 16 Geroler (see Figure 17).

26. Reposition motor in vise with output shaft down. 32. Align case drain hole and pressure relief hole in
Clamp across edges of retainer as shown in Geroler with case drain hole and pressure relief
Figure 16. hole in bearing housing. Install Geroler on bearing
housing (see Figure 17). Retain rollers in outer
27. Pour a small amount of light oil inside the output Geroler ring if they are loose.
shaft.
33. Install valve drive in Geroler.
28. Install 2 studs (earlier models), diagonally opposed,
in bolt holes of bearing housing (see Figure 16). If 34. Apply a light film of petroleum jelly on 95,0 mm [3.74
you replace studs with bolts, use 2 studs for align- inch] I.D. seal. Install seal in valve plate.
ment purposes when stacking parts.
35. Align case drain hole in valve plate with case drain
29. Apply a light film of petroleum jelly on 95,0 mm [3.74 hole in Geroler. Install valve plate (seal side toward
inch] I.D. seal. Install seal in bearing housing (see Geroler) on Geroler as shown in Figure 17.
Figure 16).
Timing Step No. 2 — Locate slot opening in valve plate
30. Install drive in output shaft (insert longer splined end which is in line with largest open pocket of Geroler (see
of drive first), (see parts drawing on page 3). Figure 17).

36. Use the following procedure for installing the valve

31. Apply petroleum jelly on 2 seals, 6,1 mm [.24 inch]
on the valve plate.

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 6000 Series Char-Lynn Motors

Timing Step No. 3 — Locate any one of the side open- 40. Apply petroleum jelly on inner and outer face seals.
ings of the valve that goes through to the face of the Install seals on balance ring as shown in Figure 20.
valve. Line up this side opening in the valve with open
slot of valve plate that is in line with largest open pocket Important: Install face seals in the positions shown in
of Geroler. Rotate valve clockwise (1/2 spIine tooth) to Figure 20 or the motor will not operate properly. Do not
engage valve with the valve drive spline, alignment force or bend these face seals. Any damage to these seals
reference shown in Figure 17 (above). This procedure will affect the operation of the motor.
provides standard timing when pressurized as shown in
Figure 18 (below).

Standard Pressure in
timing
Pressure in

Timing Figure 21
clockwise
rotation 41. Align balance ring assembly pins with 2 holes in
Clockwise valve housing (see Figure 21). Install balancing ring
rotation subassembly in valve housing.
Figure 18
42. Insert your finger through port of housing. Apply
37. Apply clean grease on 3 balance ring assembly pressure to side of balance ring assembly. Hold ring
springs. Install springs in 3 holes located inside bore in position until valve housing is in place (see Figure
face of valve housing (see Fig. 19). 21). Align case drain hole in housing with case drain
hole in valve plate. Install valve housing against
valve plate (see Figure 22).
Valve housing Balance Ring Spring (3)

Case Drain
Seal
Seal

Figure 19
Figure 22
38. Apply a light film of petroleum jelly on 7,6 mm [.30
inch] I.D. seal. Install seal in case drain groove of Note: After installing valve housing on valve plate, check between body
parts of motor for unseated seals.
valve housing.
Plug
assembly
39. Apply a light film of petroleum jelly on 92,3 mm [3.63
inch] I.D. seal. Install seal in outside seal groove of
valve housing.
Inner seal Outer seal
Pin
Check
plug
assembly

Bolt
Balance ring
Figure 23

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6000 Series Char-Lynn Motors

43. Install and finger tighten 2 bolts (or studs for earlier 44. Install 2 check plug assemblies (ball, spring, plug
models) opposite alignment studs. Remove align- with seal). Also install case drain plug with seal, parts
ment studs and install remaining bolts (or studs and shown in Figure 23 and plug torque shown in
4 nuts for earlier models). Torque bolts (or nuts) to 98 Figure 24.
Nm [864 lb-in/ 72 lb-ft], in sequence (see Figure 24).

Drain plug torque to

3 1 17 Nm [150 lb-in]
(lubricated Threads)
Char-Lynn ®

Product number

Eaton Corp. Hydraulics Div.

Eden Prairie, MN 55344 Check plug torque to
7-14 Nm [60-120 lb-in]
(lubricated Threads)
2 4

Figure 24

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 6000 Series Char-Lynn Motors

Wheel motors
A different bearing housing is used on
wheel motors (see Figure 25). Other
than this, the parts are the same as the Key
standard motor and the same disassembly Seal Retainer
and reassembly procedures apply.

Bolt

Shaft seal
Bearing housing
Back-up ring
(if supplied)
Dust seal Nut
Figure 25

Standard/Wheel motor with 4.9 [.19]

MAX
extreme duty seal guard
Installation of extreme duty seal guard:
After completing assembly of the shaft and
bearing assembly into the bearing housing,
press the Extreme Duty Seal Guard onto
the shaft with a tool that will provide an
even push over the seal. This tool must
bottom out against the front retainer and
provide a 4.9 mm [.19 inch] stop for the
extreme duty seal guard. (Applicable for
standard and wheel motors)

Figure 26

Bearing housing

Front retainer

Extreme
duty
seal
guard

Figure 27

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6000 Series Char-Lynn Motors

Bearingless motors
Mounting
This motor is the same as the standard flange
without the shaft/bearing assembly,
bearing housing and retainer. The mounting
flange replaces the bearing housing (see
Figure 28). Follow same disassembly and
reassembly procedures as rear section of
standard motor.
Important: Loctite® information for bear-
ingless motor below.

Drive
Seal
Seal
Figure 28

Important: This motor requires Loctite in

threaded holes of mounting flange.
Follow these procedures:
Adequate Loctite penetration and sealing
depend highly on cleanliness and dryness
of threads. Use a non-petroleum base
solvent to clean excess oil from threads
of flange after disassembly. You may need
to use a tap to clean threads of excess
old Loctite. Then, after you have fully
reassembled the motor, apply 2 to 3 drops
of Loctite no. 290 at top of threaded holes
(see Figure 29). Attention:
NNote: Allow Loctite 5 minutes for thread Do not use more
than 3 drops of
penetration before installing motor
Loctite on
on gear case. threaded portion.
Figure 29

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 6000 Series Char-Lynn Motors

Motors with shuttle and, or seal guard

Seal Guard Add-on Option

Plug/O-ring*
S/A (9/16-18)
Torque to
23 Nm [200 lb-in]
(Lubricated
Thread)

Plug/O-ring
S/A (3/8-24)
Torque to
5 Nm [50 lb-in]
(Lubricated
Thread)

Enlarged
parts
drawings

Dash
pot
Poppet Piston
Plug/O-ring Poppet Optional
Spring seal guard
S/A (9/16-18)
Torque to Spring
41 Nm [360 lb-in] Dash Plug/
(Lubricated thread] pot Oring
S/A

* Plug/O-ring S/A must be removed and

drain line added for shuttle valve operation.

How to order replacement parts

Char-Lynn ® Date code
Each order must include the following: Product number 00 00
1. Product number 4. Part number
2. Date code 5. Quantity of Parts
Week of Last
3. Part name Eaton Corp. Hydraulics Div. Year 01 Nu,bers (S)
Eden Prairie, MN 55344
For More Detailed Information Contact Eaton Corp. Hydraulics Thru 52 of Year
Division 15151 Highway 5 Eden Prairie, MN 55344. Product Number
Specifications and performance data, Catalog No. 11-878 000 0000 000
Replacement parts numbers and kit information.
—Part information 6-159 for 6000 series
Product line Product Engineering
Identification Identification Change
Number Number Code

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6000 Series Char-Lynn Motors

Product numbers—6000 Series motors

Use digit prefix —112-, 113-, or 114- plus four digit number from charts for complete product
number—Example 114-1047.
Displacement cm3/r [ in3/r ] and Product Number
Mounting Shaft Ports 195 245 310 390 490 625 985
[11.9] [ 15.0] [19.0] [23.9] [30.0] [38.0] [60.0]
1-1/2 inch Straight 1-5/16 O-ring 112-1064 -1065 -1066 -1067 -1068 -1107 -1069
40 mm Straight G 1 (BSP) 112-1094 -1095 -1096 -1097 -1098 — -1099
Standard
1-5/16 O-ring 112-1058 -1059 -1060 -1061 -1062 -1109 -1063
1-1/2 Inch
17 T Splined G 1 (BSP) 112-1088 -1089 -1090 -1091 -1092 — -1093
40 mm Straight G 1 (BSP) 113-1082 -1083 -1084 -1085 -1086 -1100 -1087
Wheel
Motor 1-3/4 Inch Tapered 1-5/16 O-ring 113-1070 -1071 -1072 -1073 -1074 -1093 -1075
1-5/16 O-ring 114-1031 -1032 -1033 -1034 -1035 -1055 -1036
Bearingless
G 1 (BSP) 114-1043 -1044 -1045 -1046 -1047 — -1048

114-1047

Product numbers – 6000 Series (Big 6)

Mounting type - Standard (Code H), 4 Bolt: • 160,0 [6.30] Pilot Dia.
• 18,01 [.709] Dia. Mounting holes
• 200,0 [7.87] Dia. Bolt circle
Output Shaft - Straight (Code 21)
Ports - G1 (BSP) Staggered G 1/4 Case drain (Code C)
Paint - Low gloss black

Use digit prefix —112- plus four digit number from charts for complete
product number—Example 112-1215.
Orders will not be accepted without three digit prefix.
Displacement cm3/r [ in3/r ] and Product Number
Mounting Shaft Ports 310 390 490 625 737 800 985
[19.0] [23.9] [30.0] [38.0] [45.0] [49.0] [60.0]
Standard 50 mm Straight G 1 (BSP) 112-1217 -1218 -1215 -1216 -1247 -1219 -1220

112-1215

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 6000 Series Char-Lynn Motors

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Document No. C-MOLO-TS009-E1 All trademarks are property
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