Disassembly and Inspection Procedures PREPARATION BEFORE DISASSEMBLY Before   disconnecting   hoses,   thoroughly   clean   off   all outside  dirt  around  fittings.    (After  disconnecting  hoses and before removing from vehicle, IMMEDIATELY plug portholes.)    Drain  fluid  and  finish  cleaning  and  drying assembly  before  placing  on  a  clean  work  surface.    (A piece   of   clean   paper   makes   an   excellent   disposable top.)     All     disassembled     parts     should     be     cleaned separately  in  clean  petroleum-based  solvent  and  blown dry  with  air  to  avoid  nicks  and  burrs.    Discard  all  seal and  seal  rings  as  they  are  removed  from  Torqmotor. Use Ross Gear Division or OEM approved service parts. WARNING:  SINCE  THEY  ARE  FLAMMABLE, BE   EXTREMELY   CAREFUL   WHEN   USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. WARNING:   WEAR   EYE   PROTECTION   AND BE   SURE   TO   COMPLY   WITH   OSHA   OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. CAUTION:   Never   steam   or   high   pressure wash  hydraulic  components.    Do  not  force or abuse closely fitted parts. REPLACEMENT    OF    HIGH    PRESSURE    SEAL    (5) WITHOUT COMPLETE TORQMOTOR Ô   DISAS- SEMBLY (Reference Exploded Assembly View) 1. Remove  and  discard  dirt  seal  (1)  and  retaining ring   (2)   from   Torqmotor.      [Some   applications may not require dirt seal (1).] 2. Completely fill Torqmotor with oil.  Plug "A" and "B"   ports   and   set   Torqmotor   in   a   clean   pan. Place a clean rag around the coupling shaft seal area    of    the    housing    to    prevent    oil    spray. Carefully   grip   coupling   shaft   with   appropriate wrench  and  rotate  coupling  shaft  rapidly  in  a counter-clockwise direction. Oil pressure generated    by    Torqmotor    will    eject    backup washer (3), washer (4) and seal (5). 3. Select  the  proper  seal  assembly  tools  for  the  1 1/4 inch (31.8 mm) or 1 1/2 inch (38.1 mm) seal diameter  coupling  shaft  involved.    See  Figures 1, 2 and 3, page 2. Insert  the  selected  seal  compression  ring  tool (Figure   3),   with   chamfered   end   inward,   into housing  (6)  until  it  bottoms  out.    Assemble  the selected    seal    thimble    tool    (Figure    1)    over coupling   shaft   (11).      Coat   new   seal   (5)   with clean  grease  and  assemble  over  seal  thimble with  lip  side  inward.    Push  new  seal  (5)  into housing (6) with the appropriate seal driver tool (Figure  2).    Remove  seal  driver,  thimble  and compression tools. 4. Hold   washer   (4)   between   thumb   and   index finger and slightly collapse washer and assemble  into  housing  (6).    Assemble  back-up washer  (3)  tab  side  out,  and  retaining  ring  (2). Be sure rounded edge of retaining ring is faced inward, and that back-up washer tab is between ends    of    retaining    ring.        Be    sure    the    new retaining  ring  (2)  is  the  same  thickness  as  the one  removed.    (Seal  kit  contains  two  retaining rings  to  select  from.)  Apply  a  small  amount  of clean  grease  to  the  back  side  of  new  seal  (1) and assemble into housing (6) if required. TORQMOTOR DISASSEMBLY (Reference Exploded Assembly View 1. Place  Torqmotor  in  a  vise,  clamping  down  on the  housing  (6)  port  bosses  with  the  coupling shaft (11) pointed down. WARNING:   IF   THE   TORQMOTOR   IS   NOT FIRMLY  HELD  IN  THE  VISE,  IT  COULD  BE DISLODGED DURING THE SERVICE PROCEDURES, CAUSING INJURY. 2. If the end cover assembly (23) has a valve (28), scribe a line on housing (6) in some manner in line     with     the     port     in     the     end     cover     for reassembly  orientation.    Loosen  the  two  plugs (25)   with   a   3/16   inch   Allen   wrench,   for   later disassembly.    Remove  the  seven  special  bolts (24) using a 9/16 inch thin wall socket.  Inspect bolts  for  damaged  threads,  or  the  sealing  ring under the bolt head.  Replace damaged bolts. 3. Remove end cover assembly (23) and sea! ring (7)  by  inserting  screwdriver  between  end  cover assembly  and  sleeve  (22).    Pry  up  end  cover assembly    and    lift    from    unit    with    seal    ring attached.      Discard   seal   ring   (7).      It   may   be necessary to use a chisel and hammer to break the end cover loose. 4. If  the  end  cover  (23)  has  valve  (28)  and  the previously loosened plugs (25), remove the two plugs and O-rings (26). CAUTION:   Be   ready   to   catch   two   springs (27) and valve (28) that will fall out of the end cover valve cavity when the plug assemblies are removed. Thoroughly  wash  cover  in  proper  solvent  and blow  dry.    Be  sure  the  cover  valve  apertures, including  the  internal  orifice  plug,  are  free  of contamination.      Inspect   end   cover   for   cracks and  the  bolt  head  recesses  for  good  bolt  head sealing surfaces.  Replace cover as necessary. NOTE: O-ring (26) is not included in seal kits but is serviced separately if required. 5. Remove    commutator    ring    (21),    commutator (19),  seal  ring  (20),  and  manifold  (18)  by  using two  of  the  special  bolts  (24)  as  a  lifting  tool- insert the two special bolts Into two holes and lift out the previously mentioned parts. 6. Remove  seal  ring  (20)  from  commutator  (19), using  an  air  hose  to  blow  air  into  ring  groove until seal ring is lifted out and discard seal ring. Inspect  commutator  and  commutator  ring  (21) for   cracks   or   burrs.      Inspect   commutator   for wear,  scoring,  spalling  or  brinelling.    If  any  of these conditions exist, replace commutator and commutator ring as a matched set. 7. Remove manifold plate (17) by again using two special bolts (24) as a lifting tool.  Inspect 6