DRIVE MOTOR 2.

12
General Information

C1129

The basic geroter design uses a combination of mechani-

cal and hydraulic principles that are utilized in the high
torque, low speed motors.
The outer ring ( fig. C153 ) of the geroler assembly is
similar to an internal gear that is held in a fixed position
by securing it to the motor housing. The rotating inner
gear, called a star, orbits inside the secured outer ring.

C153
Because of the different number of teeth on the star and
outer ring, the star rotates in an eccentric circular orbiting
motion from the housing center line. ( fig. C154 )

C154

2-27
 DRIVE MOTOR 2.12
A drive shaft is used to transmit the rotation of the star to
the output shaft. The drive shaft has crowned external
splines to match the internal splines in the star and output
shaft. This type of drive is used because the star center
line continuously changes during rotation.

2 As the star orbits, it causes a continuous opening and

closing of the outer ring fluid pockets. Half of these fluid
pockets are subject to fluid pressure, causing star rotation,
and the opposing half are connected to the return line.
When pressure is introduced into the fluid pockets on the
right side of the star ( fig. C156 ) the output rotation will
be counterclockwise. When the fluid pockets on the left
side of the star are pressurized the output shaft rotation
will be clockwise.

C156

To seal the fluid pockets the torque motor incorporates a

rotating roller type seal. ( fig. C157 ) This type of a
rolling seal reduces friction at the star points providing
increased efficiency and reduced component wear.

C157

2-28
 DRIVE MOTOR 2.12
The geroler (fig. C2299), is both a fluid displacement 8 point star Roller (9)
motor and a gear reducer. It provides 8 times (the number
of star points) greater power per revolution than a gear,
vane or piston type motor. This means that 8 times the
greater torque can be developed at one eighth the speed
without further gear reduction.

Fluid pockets (9)

2

C2299

Example shown in fig. C166 is one complete star orbit, or

one sixth of the output shaft rotation.The star must travel
through 6 complete orbits for each single rotation of the
output shaft creating a speed reduction of 6 to 1. The use
of 7 fluid power pockets with the 6 to 1 ratio provides 42
fluid power cycles per each complete shaft revolution.
NOTE: Actual star point count is 8. This is only an
example.

C166

2-29
 DRIVE MOTOR 2.12
For smooth and continuous motor output rotation, the C1891
torque motor utilizes a disc valve which operates in syn-
chronization with the geroler star. The disc valve arrange-
ment consist of a stationary balance plate, rotating disc
valve and a stationary valve plate.
The disc valve contains an inlet fluid passage port for

2 each star valley and a return fluid passage point.

A separate crowned driveshaft is used to synchronize the
disc valve and the geroler star so that they turn as one. To
accept fluid from the disc valve, the valve plate also con-
tains internal porting passages to each outer ring pocket
area.

C1129
Fluid enters the housing through the inlet port and is valve opens to allow the fluid in the pocket are to pass
directed to the balance plate. The balance ring contains an back through the valve plate, disc valve, balance plate
inner and outer seal to separate the high and low pressure and out through the housing return port, as the pocket
fluid passages. Fluid passes through the stationary bal- closes.
ance plate to the rotating disc valve. The rotating disc The disc valve is timed to the geroler rotor star to govern
valve ports the fluid to the stationary valve plate and the the the inlet fluid flow to the output shaft rotation.If the
proper side of the geroler pockets causing the rotor star to timing of the disc valve to the geroler star is off one
turn. tooth, the relationship of input fluid flow to output motor
As the rotor star rotates, and each fluid pocket reaches its shaft rotation will be reversed.
full open position, the return porting in the rotating disc

2-30
 DRIVE MOTOR 2.12
Removal
1 Remove any attachment, raise the boom arms and Upper fill check
engage the boom support pins.

WARNING
To prevent personal injury do not work under the
boom arms without the boom supports engaged.

2 Raise the loader securely off the ground.

2
Oil drain plug
3 Remove the wheels on the side to be repaired. C1888
4 Drain the oil from the final drive housing. Be pre-
pared to contain approximately 1.9 gal (7 l) of fluid. (fig.
C1888) Inspection cover
5 Remove the seat and hydrostatic shield.
6 Remove the final drive inspection cover located
between the axles of the final drive housing.(fig. C2073)
7 Disconnect the chain as outlined in Section 3.

C2073

8 Remove the 2 high pressure hoses from the drive Hi - pressure hoses
motor. ( fig. C2074 ) Cap the open hose ends and fittings
to prevent contamination.

IMPORTANT
When making repairs to the hydraulic system, keep
the work area and parts clean. Use caps and plugs
on all open line and ports.
C2074

9 Disconnect the brake line hose and the case drain

hose from the drive motor. Cap the hoses and adapter fit-
tings in the drive motor. (fig. C2082)
10 Remove the adapter fittings from the drive motor. Brake hose
Case drain hose
Plug the open ports in the drive motor to prevent contam -
ination.

C2082

2-31
 DRIVE MOTOR 2.12
Removal
12 Remove the jam nuts, mounting nuts and lock wash- Nuts
ers from the 4 mounting bolts retaining the drive motor to
the final drive housing. (fig. C2081) Hold the head of the
bolts from inside the final drive housing. (fig. C2077)

2 13 Remove the drive motor. Seal the drive motor with

silicone upon reassembly.
14 Upon reassembly torque the 4 mounting nuts to 80 ft
lbs (110.4 N m).
15 If the drive motor replacement is being performed
because of major parts failure, such as geroler damage,
the hydraulic system must be checked for contamination C2081
and flushed if necessary as outlined in Section 2.7.
Torque motor mounting bolt

C2077

16 Remove the drive motor sprocket and bolt. Visually Drive sprocket
inspect the drive motor sprocket. Check for worn or dam-
aged teeth on both the outside of the sprocket, and the
inside spline (fig. C2079).

C2079

17 Install the sprocket, machined washer, lock washer Apply loctite

and bolt. Apply Loctite 242 (blue) to the threads of the
bolt before torquing (fig. C2080) and torque the bolt to 25
ft lbs. (34 Nm).

C2080

2-32
 DRIVE MOTOR 2.12
Replacement Clean sealing area
1 Clean the mounting areas thoroughly that need to be
sealed with silicone. (fig. C2078, C2076)

2
C2078

Clean sealing area

C2076

2 Apply a bead 1 / 4 of an inch thick around the drive Apply silicone

motor bearing retainer and around each mounting hole.
(fig. C2079)
3 Install the drive motor and sprocket assembly to the
final drive housing.
4 Install the 4 bolts, lockwashers and mounting nuts
and torque to 80 ft lbs (115 Nm.)
5 Install the 4 jam nuts. Torque the jam nuts to 40 ~ 60
ft lbs (54 ~ 81 Nm.)

C2079

6 Replace the master link in the dive chain. Section 3.

shows chain replacement procedure.
7 Add oil to the final drive housing unit it trickles out
the upper check plug hole. This will require approximate-
ly 1.9 gal (7 litres) of 10w30 API SJ oil. (fig. C1888)
Upper check plug

C1888

2-33
 DRIVE MOTOR 2.12
IMPORTANT Apply sealing gasket
When making repairs to the hydraulic system, keep
the work area and parts clean. Use caps and plugs
on all open line and ports.

2 IMPORTANT
Inspect fitting o-rings and flares for marks or dam-
age. Replace if necessary.
C2076

8 Install the adapter fittings to the drive motor.

9 Install the brake lines to the drive motor. (fig. C2082)

WARNING
Use caution when dealing with hydraulic fluid under Brake hoses
pressure. Escaping fluid under pressure can pene-
trate the skin and cause serious injury.

10 Install the high pressure drive hoses. (fig. C2074)

11 Clean the final drive housing and inspection cover
thoroughly before sealing the transmission. Apply the
C2082
gasket Seal to the transmission. (fig. C2076)

WARNING Hi - pressure hoses

To prevent personal injury never make repairs to the
hydraulic system while the engine is operating.

12 Install the inspection cover. When installing the nuts,

do not over tighten. The mounting torque should not
exceed 15 lbs ft. (15 Nm)
14 Start the engine and check for hydraulic leaks. Do
not use your hands to trace hydraulic leaks. Shut off the
engine and inspect each fitting for proper torque.
15 Install the wheels and torque the nuts at 100 to 110 ft C2074
lbs. (136 to 149 Nm.)
16 Install shields and seat, let loader down to ground
Torque the wheel nuts
and test drive to check performance.

C1658

2-34
 DRIVE MOTOR 2.12
Parts Illustration
Danfoss OMT FL 1 C1892
Diagram C1892 Index
1. Name plate
2.
3.
4.
5.
6.
Bolts
Valve housing
Spring washer
Spacer
O-ring seal
2 3

4
2
7. O-ring seal 5
8. Valve drive shaft 6
9. Channel plate 7
10. Disc valve 11
11. Balance plate
12. Guide pin 10
13. O-ring seal
14. Guide pin 9
15. Gearwheel set
16. Intermediate plate
17. O-ring seal
18. Conical seal ring 12
19. Cardan shaft
8

13

14
15 18

13 19

16
Fig. C1892 shows an exploded view of the hydraulic
torque motor. Before disassembling the torque motor,
17
clean the outer surface of all loose dirt and grease and dry
with compressed air. Be sure all openings are plugged to
prevent solvent or soap entering the torque motor.

WARNING IMPORTANT
When making repairs to the hydraulic system, keep
To avoid eye injury, use safety goggles when clean-
the work area and parts clean. Use caps and plugs
ing with compressed air.
on all open line and ports.

2-35
 DRIVE MOTOR 2.12
Parts Illustration
Danfoss OMT FL Brake 3 C1893
Diagram C1893 Index 1

1. Bearing nut

2 2.
3.
4.
5.
6.
Bearing, small
Screw
Bearing housing
O-ring seal
Spring
6
2

3
4

7. Spring 7
8. Piston
9. O-ring seal 8
10. Ring
11. O-ring seal 9
12. O-ring seal
13. Inner brake disc
10
14. Outer brake disc
15. Spacer disc
11
16. Bearing housing
17. Bearing 12
18. Splined shaft
19. O-ring seal
20. Shaft seal
21. Front cover 13
22. Dust seal ring 14
23. Screws 15

18
16

17

19

Fig. C1893 shows an exploded view of the hydraulic

torque motor brake. Before disassembling the torque
motor and or brake, clean the outer surface of all loose 20
dirt and grease and dry with compressed air. Be sure all
openings are plugged to prevent solvent or soap entering 21
the torque motor.
22
WARNING 23
To avoid eye injury, use safety goggles when clean-
ing with compressed air.

2-36
 DRIVE MOTOR 2.12
Disassembly Mark sections
1 Place the drive motor in a vise with the output shaft
facing down. Clamp the motor to the vise, holding it by
the mounting flange area. Do not clamp the motor on the
housing as excessive pressure will cause distortion.
2 Mark a line across the various sections of the drive
motor to assist in reassembly. (fig. C2287)
2
C2287

3 Remove the small allen head socket plug located Remove restrictor plug
between two of the section bolts.( fig. C2288)

C2288

4 Insert an allen wrench into the open hole and remove

the set screw restrictor. (fig. C2289)

Remove restrictor

C2289

5 Remove the 4 bolts from the drive motor valve hous-

Remove section bolts
ing. (fig. C2290) Upon reassembly, torque the bolts in a
criss cross pattern at 130 ~ 135 ft lbs. (177 ~ 183.5 Nm)

C2290

2-37
 DRIVE MOTOR 2.12
Disassembly (cont’d) Remove shuttle
valve plugs
6 Insert a small screwdriver into the mounting holes of
the valve housing assembly and remove the 2 shuttle
valve plugs, one each side. (fig. C2291, 2293)

2
C2291

Shuttle
valve plug

C2292

7 Insert a small screwdriver into the shuttle valve plug

Shuttle valve springs
hole and retrieve the springs. (fig. C2293) There is one on
either side.

C2293

8 Push out the shuttle valve poppet using the screw-

Shuttle valve poppet
driver. (fig. C2294)

C2294

2-38
 DRIVE MOTOR 2.12
Disassembly (cont’d)
9 Carefully lift the valve housing straight up. (fig.
C2295) Place your fingers under the valve housing to
hold the channel plate in place.

2
C2295

10 Remove the channel plate. (fig. C2296)

Channel plate

Disc valve

C2296

11 Remove the disc valve and balance plate from the Valve housing
valve housing section. (fig. C2297, C2298)
12 Inspect the parts for wear and replace as required.
Replace all seals with new when assembling the drive
motor.
Balance plate

Spacer
Locating pin

Notch

C2297 Spring washers

Channel plate

Disc valve

C2298

2-39
 DRIVE MOTOR 2.12
Disassembly (cont’d)
13 Separate the geroler section from the rest of the
motor. (fig. C2300, C2303) Place your fingers between
the sections as you lift the geroler section to prevent the
rollers and gear from spilling out.

2
C2300

C2303
14 Inspect the gears and rollers for wear such as scratch-
es and pitting. (fig. C2301, C2302) Replace worn parts as
required. Do not mix the position of the rollers in the ger-
loer section housing.

C2301

C2302

2-40
 DRIVE MOTOR 2.12
Disassembly (cont’d)
Cardan shaft (drive)
15 Remove the cardan (drive) shaft (fig. C2304).
16 Remove the intermediate spacer (fig. C2305) .
Replace the seal with new item at time of assembly.

2
C2304

Intermediate spacer

C2305

17 A special tool will be required as shown in fig. Special tool

C2306 to remove the bearing nut (fig. C2307). Tool
shown was made using 1/2 in. X 1 in. X 3 in. long
(12mm x 25mm x 76mm L) material. Two holes were
drilled and tap 60mm apart, to accept 6mm X 30mm 3 in.
machine screws. (76mm)

6mm machine screws

2.4 in.
(60 mm)
C2306

Bearing nut

C2307

2-41
 DRIVE MOTOR 2.12
Disassembly (cont’d) Special tool
18 Place the special tool on the bearing nut and remove
the bearing nut. (fig. C2308, C2309).

2
C2308

Bearing nut

C2309

19 Remove the drive motor from the vise and remove Retaining screws
the screws retaining the front cover to the bearing hous-
ing. (fig. C2310, C2311). Replace the seals with new at
time of assembly.

C2310

Front cover

C2311

2-42
 DRIVE MOTOR 2.12
Disassembly (cont’d) Output shaft and large bearing
20 Use a press and appropriate sized arbor to push the
output shaft from the bearings. (fig. C2312).

2
C2312

21 Remove the small bearing from the housing. (fig. Small bearing
C2313). Inspect both bearings and races. Replace as
required.

C2313

22 Remove the bolts from the around the bearing hous- Bearing housing bolts
ing. (fig. C2314).

C2314

23 Separate the bearing housing sections. (fig. C2315) A

Separate section
mallet may be required to assist removal.

C2315

2-43
 DRIVE MOTOR 2.12
Disassembly (cont’d) Bearing housing
24 Remove the bearing housing (fig. C2316).

2 Seal

C2316

25 Remove the brake springs from the brake piston. (fig.

C2317) There are inner and outer springs. Inner and outer spring

C2317

26 Remove the piston from the housing by pushing

Piston
through from the output shaft side. (fig. C2318)

Seals

C2318

27 Remove the brake disc assemblies. Note the positions

of the steel and fibre plates. (fig. C2319). Check the
plates for wear and replace as required.

C2319

2-44
 DRIVE MOTOR 2.12
Assembly Output shaft and bearing
1 Install the output shaft to the housing. (fig. C2321)

2
C2321

2 Install the front cover to the housing and torque the Front cover
screws to 8.9 ft lbs (12 Nm). (fig. C2322). Use new seals
when assembling the motor.

C2322

3 Install the brake disc spacer ring to the housing. (fig. Spacer ring
C2320)

C2320

4 Install the brake disc plates. (fig. C2323, C2324, Steel plate
C2319) Start with a fibre plate, add a steel plate, then
fibre and so on until the last plate to be installed is a fibre
plate.

Add fibre plate first

IMPORTANT
NOTE: The fibre plates are also called outer plates
due to the “teeth” outside of the plate.
C2324

2-45
 DRIVE MOTOR 2.12
Assembly (cont’d) Add steel plate second
5 Continue adding plates, 12 fibre, 11 steel plates, to
the housing. (fig. C2323, C2319)

2
C2323

Brake discs

C2319

6 Install the piston to the housing, over the brake discs. Piston
(fig. C2318) Use new seals when assembling the motor.
Align one of the piston spring pockets with the hydraulic
inlet port opening in the housing. (fig. C2316)

Seals

C2318

Bearing housing

Align spring to hydraulic port

Springs

C2316

2-46
 DRIVE MOTOR 2.12
Assembly (cont’d)
7 Install the bearing housing bolts and torque to 46.5 ft
lbs. +/- 2 ft lbs. (63 Nm +/- 3 Nm) (fig. C2314)

Housing bolts
2
C2314

8 Install the small bearing to the output shaft (fig.

Small bearing
C2313) in the following sequence:
a. Apply pressure, 175 psi (12 bar), to the brake ports
to release the brakes.
b. Press the bearing onto the output shaft with a force
of 780 pounds of force (350daN), while rotating the hous-
ing back and forth. Be sure to press only on the inner race
of the bearing.
c. Remove the brake release pressure before remov-
ing the force acting on the bearing.
d. Install the bearing nut and torque to 45 ft lbs. (60
Nm) Strike the nut with blows from a mandrel and ham- C2313
mer to prevent the nut from loosening.
Bearing nut

C2309

9 Install a new seals to the intermediate plate. (fig.

C2325). Apply petroleum jelly to the cup seal to retain in Seals
position.

C2325

2-47
 DRIVE MOTOR 2.12
Assembly (cont’d)
Pin
10 Install the intermediate plate to the housing. (fig.
C2326). Note the alignment pin used to locate the plate to
the notch in the housing. Notch

2
C2326

11 Install two studs if available to assist assembly. (fig. Studs

C2327).

C2327

12 Install the cardan (drive) shaft to the output shaft. Cardan shaft
(fig. C2328).

C2328

13 Note the holes in the intermediate spacer and the

geroler section housing. (fig. C2329). Align these holes Seal
when installing the geroler section to the housing.

Holes

C2329

2-48
 DRIVE MOTOR 2.12
Assembly (cont’d) Install geroler section

14 Install the geroler section the housing. (fig. C2330)

Place a hand under the geroler to prevent the pieces from
falling out.

The following procedures must be followed closely

2
for proper motor rotation. C2330

15 Mark the gearwheel set rotor at the point where the Mark the gearwheel
top of a spline tooth is opposite the bottom of a tooth in
the external rotor teeth. (fig. C2331).

C2331

16 Mark the bottom of a spline tooth on the valve drive.

(fig. C2332).

Mark the valve drive

C2332

17 Install the valve drive lining up the marks on the

Line up the marks
valve drive to the gearwheel set. (fig. C2333).

C2333

2-49
 DRIVE MOTOR 2.12
Assembly (cont’d) Seal
18 Install the channel plate to the geroler section. Install
new seals when assembling the motor. (fig.C2334) Note
the alignment dowel pin and oil passage hole.

2
Hole
Dowel pin

C2334

19 Install the disc valve to the valve drive. (fig. C2335) Align timing mark with hole
Align the mark on the valve drive with a hole in the outer
rim.

Hole

Timing mark

C2335

20 Turn the disc valve counter clockwise until the two Turn counter clockwise
parts engage. (fig. C2336).

Timing mark

Disc valve hole

C2336

21 Install new seals to the balance plate, install the Valve housing
springs and install the balance plate to valve housing.
(fig. C2297). Note the locating pin in the valve housing
and the notch in the balance plate.
Balance plate
Seal

Spacer
Locating pin

Notch
Spring washers
C2297

2-50
 DRIVE MOTOR 2.12
Assembly (cont’d) Spacer
22 Apply petroleum jelly to the spacer. (fig. C2337)
Install the spacer to the valve housing. (fig. C2338)

2
C2337

Spacer

C2338

23 Install the valve housing to the drive motor. (fig. Valve housing
C2339).

C2339

24 Install the shuttle valve piston. (fig. C2294).

Shuttle valve piston

C2294

2-51
 DRIVE MOTOR 2.12
Assembly (cont’d) Shuttle valve springs
25 Install the shuttle valve springs to either side of the
piston. (fig. C2293).

2
C2293

26 Install the shuttle valve plugs. (fig. C2292) Be sure to

use new seals when assembling the motor.
Seal

Shuttle valve plug

C2292

27 Install the bolts to the drive motor and torque in a

crisscross pattern to 135 ft lbs. (183 Nm).( fig. C2290).
Torque bolts

C2290

28 Install the restrictor and replace the plug. (fig.

C2289).

Restrictor

C2289

2-52