Professional Documents
Culture Documents
John Deere Spraymaster - Centrifugal Pump Repair
John Deere Spraymaster - Centrifugal Pump Repair
Description
Centrifugal Pumps handle big, high capacity farm spraying Available in a variety of models, including lightweight
jobs with ease. Use them for spraying liquid fertilizers and polypropylene (pump portion only) pumps for resistance to
other chemicals, including wettable powder slurries for weed corrosive liquids such as acid-based fertilizers. This manual
control. Make short work of other farm jobs - filling nurse will cover the installation of the basic drive configurations
tanks, watering seed beds, and transferring liquids. available for gear, belt, hydraulic and direct-drive centrifugal
pumps. Read manual completely before attempting to install
or operate the pump.
PM9305CHM3C
Cast Iron, Hydraulic-Driven
Centrifugal Pump
Max. Flow Rate: .......... 180 gpm
Max. Pressure: ............. 160 psi
Ports: ...................... 2" NPT inlet
2" NPT outlet
Hydraulic Ports: 1/2" NPT inlet
1/2" NPT tank
300C-JD
1 05-02
Contents
300C-JD 2
05-02
General Safety Information
Notes are used to notify of installation, operation, or Do not pump at pressures higher than the maximum
maintenance information that is important but not safety recommended pressure.
related.
Operate the Pump between a temperature range of 45o
to 140o F [7o to 60o C].
Caution is used to indicate the presence of a hazard,
which will or can cause minor injury or property damage Make certain that the power source conforms to the
if the notice is ignored. requirements of your equipment.
Danger is used to indicate the presence of a hazard that Drain all liquids from the system before servicing.
will result in severe personal injury, death, or property
damage if the notice is ignored. Secure the discharge line before starting the Pump. An
unsecured discharge line may whip, resulting in personal
injury and/or property damage.
Do not pump flammable or explosive fluids such as
gasoline, fuel oil, kerosene, etc. Do not use in explosive Check all hoses for weak or worn condition before each
atmospheres. The Pump should only be used with liquids use. Make certain that all connections are tight and
compatible with the Pump materials. Failure to follow secure.
this notice can result in severe personal injury and/or
property damage and will void the product warranty. Periodically inspect the Pump and the system
components. Perform routine maintenance as required
Never use your hand to check the condition of hydraulic (See Maintenance).
lines or hoses. If hydraulic fluid penetrates the skin, get
medical attention immediately. Failure to get proper Use only pipe, hose, and hose fittings rated for maximum
medical attention may result in loss of limb or life. The rated pressure of the Pump or the pressure at which the
safest way to check hydraulic lines is by holding a piece Pressure Relief Valve is set at. Do not use used pipe.
of cardboard next to the hydraulic line or hose.
Do not use these Pumps for pumping water or other
liquids for human or animal consumption.
The sound pressure level of the Pump may exceed
86dBA. Observe all safety precautions when operating
the Pump within close proximity for extended periods
by wearing hearing protectors. Extended exposure to
elevated sound levels will result in permanent loss of
hearing acuteness, tinnitus, tiredness, stress, and other
effects such as loss of balance and awareness.
300C-JD
3 05-02
Plumbing Installation
Preliminary to Mounting
This line (1/4"vinyl tubing) prevents air lock and allows
Before mounting the Pump, check to see that it can be
the pump to prime itself by bleeding off trapped air.
turned by hand (turn shaft counterclockwise). If it cannot
The small stream of liquid that returns to the tank during
be turned, open casing to check for obstructions lodged
operation is negligible. The discharge from this line
in Pump.
should be to the tank above the high liquid level.
Priming the Pump It is recommended that the discharge port be mounted
vertically at the top of the pump. This is to eliminate air
pockets and to aid priming action.
The Pump must not be run dry. Before starting the
Pump, the Suction Line and Pump must be filled Selecting the Suction Line
with liquid. The Pump must not be run unless it is
completely filled with liquid, as there is danger of To get full capacity of the pump, the suction line should
damaging the Mechanical Seal, which depends upon be the same size as the pump suction port. A smaller
the liquid for its lubrication. size can be used for lower pump output, but a suction
line must be one size larger than the discharge line
These centrifugal pumps are not self-priming. If a pump (for example, if 3/4" discharge line, use 1" suction line).
cannot be mounted below the level of liquid, mount the The suction line must be free of air leaks. Use a good
pump as near to the liquid source as practical so that a grade of suction hose that will not collapse. A relief
short pipe or hose may be used. The suction line should valve or bypass line is not necessary and is not
slope down to the pump. If not, install a foot valve in the recommended with these pumps.
suction line at the liquid source and prime by filling the
pump full before starting. Also, add a vent line that
extends from top plug in the pump casing up into the
tank. Use John Deere Spraymaster Vent Line Kit
PM34300456.
Strainer Selection
Vent
While strainers are installed on the suction side for roller Line
pumps, piston pumps and similar types, they should Agitators
be installed on the discharge side of centrifugals. Since
its primary purpose is to prevent clogging of the spray
nozzles, the line strainer is installed in the line to the Agitation Shut-off Valve
boom or spray gun (See Figure 1). A smaller strainer Line
is adequate in this position as much of the pump output Valve
is recirculated. Alternate locations are in the suction
line, if its capacity is adequate for the pump and will
not restrict the flow into the pump; or at the pump outlet, Control
Line
if it is also sturdy enough to withstand full pump Valve
Strainer
pressure.
Line
Strainer
Line Pressure
Strainer Gauge
Boom
Shut-off
Valve
Figure 1
Centrifugal Plumbing Hook-Up
300C-JD 4
05-02
Tractor PTO Installation
Series PM9400 Belt Drive Centrifugal Tumblerod Drive (Belt Drive Pump)
Pumps
Two mounting holes are predrilled and tapped on the
Series PM9400 pumps are designed for ease of adjustment arm of unit for attachment to sprayer frame.
installation and removal with tractor mounted sprayers. Use lock washers to assure secure mounting. Tumblerod
Hollow shaft models come equipped with John Deere can be connected directly to driver shaft or with an
Spraymaster’s unique locking collar designed to hold adapter.
the pump driver hub more securely on the PTO shaft
(Refer to following section for proper installation of
locking collar). Pump life is increased by reducing both
The Tumblerod must be level; the hitch pin must be
pump driver hub and PTO shaft wear due to vibration.
an equal distance between the end of the tractor PTO
shaft and the end of the pump shaft; and turn angles
To prevent pump from turning on PTO shaft, install torque
chain as follows: of greater than 45o should be avoided. Failure to
follow these rules will cause damage to the pump
1. Remove one pump casing outboard bolt (farthest drive line.
away from the PTO shaft). Using a 1/4" longer bolt This locking collar kit included with the pump holds
and two flat washers, attach a length of chain or the pump driver shaft securely on the tractor PTO shaft.
other flexible fastener to the bolt between the It is designed to increase pump life by reducing pump
washers (See Figure 2) and insert into pump casing and PTO shaft wear due to vibration. To install locking
in place of the bolt removed. Secure the other end collar:
of the torque chain to something solid on the tractor,
preferably above the pump rather than below. If it
cannot be attached to anything above the pump, it
may be fastened to the draw bar or frame directly
below the pump.
Figure 3
Allow a 1/8” Clearance
2. The torque chain must be in a straight upward or 5. Tighten screw 'A' very securely with a 3/16" allen
downward line from the pump, as any sideways pull wrench (See Figure 3).
may damage the pump bearings. The torque chain
should have some slack in it to allow the pump to 6. Tighten set screw 'B' very securely with the same
“float” on the PTO shaft during operation. wrench. This binds set screw 'A' which prevents it
from coming loose.
3. To prevent start-up shock, a spring should be
attached to the torque chain. Secure end of the
spring to something solid in the same manner as The locking collar is off-center on the pump driver
using a torque chain alone. shaft when properly installed.
300C-JD
5 05-02
PTO Shaft Mounting Belt Drive and Safety Shield Assembly (See
Figure 5)
The best PTO Shaft installation occurs when the
distance from the PTO U-joint to the hitch is equal to
the distance from the hitch to the pump U-joint. For
540 rpm PTO shafts, the distance should be 14 inches
[355.6 mm]. For 1000 rpm 1-3/8" [34.93 mm] PTO
shafts, the distance is 16 inches [406.40 mm]. For 100
rpm1-3/4" [44.45 mm] PTO shafts, the distance is
20 inches [508.00 mm] (See Figure 4).
PTO PTO
Hitch Hitch
Point Point
Figure 5
Belt Drive and Safety Shield Assembly
1. Insert the bracket into the center mounting slot on
one of the half shields.
Pump
2. Hold this half shield over the belt and corresponding
Pump pulleys while sliding the other half shield into place.
Correct Equidistant Incorrect
PTO Shaft Installation 3. Insert the carriage bolts through the two shields
PTO Shaft Installation
with the square carriage heads seating in the
square holes and tighten the wing nuts.
X and Y are equal, which X and Y are not equal,
maintains equal u-joint creating unequal u-joint 4. Insert the attachment bolt through the pedestal of
angles and prevents angles which can result the belt drive, into the threaded bracket and tighten.
fluctuations. in rpm fluctuations and
increased wear on the Series PM9000CO PTO Gear Driven
Figure 4 u-joints and pump.
PTO Shaft Mounting Pumps
If direct PTO mounting is not convenient or desired, On Series PM9000CO units, install the Pump using the
then mount the pump in a convenient position on the John Deere Spraymaster PTO Mounting Clip, which is
pull-behind sprayer and connect it to the tractor PTO designed to accommodate most tractor PTO shields.
with a "tumble rod" power shaft. When properly installed, the Clip prevents the Pump from
rotating, reduces the weight on the Pump Shaft (reducing
excessive wear on the bearings), and in most cases,
When using the above approach insure: (1) the replaces the Torque Chain. It also covers the rotating
tumble rod is level, (2) the hitch pin is the center- PTO and Pump Shaft as an added safety precaution
point, and (3) turn angles greater than 45o should when Pump is in operation.
be avoided. Failure to follow these three points can
cause "power shocks" within the pump and drive 1. When mounting the Pump Clip to the PTO shield,
units and increase wear on seals, gears, and in the make sure the Shield is not bent down. This will
case of diaphragm pumps, the diaphragms cause an additional burden on the Pump Bearings.
themselves. It may be necessary to bend the Shield back to its
original position (or higher) to allow the Clip to slide
Power shocks occur when the PTO shaft knuckle and under the Shield as shown in Figure 6.
the universal joint at the pump end of the tumble rod
turn faster on the inside of the turning angle than on Plate
Adjustment
the outside. To prevent these vibrations, the angle of
the tumble rod to the tractor PTO shaft and the angle of
the tumble rod at the pump shaft should be as close to
equal as possible. This will cancel out the fluctuations.
Figure 8.
300C-JD
7 05-02
To figure proper diameter of pump pulley, multiply motor/
engine rpm by the diameter of the motor/engine pulley Push the belt
and divide that figure by the desired pump speed. midway between d
the pulleys, check
Pump = Motor RPM x Motor Pulley Size the deflection (d)
Pulley Size Desired Pump Speed and adjust
All Models — Open Center Systems move orifice for use with closed center systems with
flow control such as John Deere closed center sys-
Models include Tank Port Adapter with built-in Check
tems. Also remove for small open center systems with
Valve Assembly and Pressure Port Adapter.
a maximum flow of 10 gpm for HM4C Model. If
HM2C and HM4C Models Only — Closed necessary, the pressure port adapter may be used
without a metering orifice installed in any closed
Center and Small Open Center Systems.
center system, provided the pressure differential
Models include Tank Port Adapter with built-in Check
across the hydraulic motor does not exceed 1800 psi
Valve Assembly and Pressure Port Adapter with three
(12.4Mpa).
different size metering orifices and HM4C models. Re-
300C-JD
9 05-02
Hydraulic Pumps
Hydraulic Pumps
Hydraulic pumps come in two basic types: There are two basic types of spool valves used in conjunc-
tion with these pumps — open and closed center. In the
• Constant displacement - which will continue to put open center valve (Fig. 12), the flow goes straight through
out its rated flow regardless of pressure, until the relief the valve when in the neutral position. This type is used for
valve bypasses the flow. constant displacement pumps where the flow should
• Variable displacement - which will produce only the never be shut off.
flow needed by the implement until the total pump output
is reached. If less than the full pump output is required, Closed Center
an automatic stroke control mechanism decreases the Spool Valve
pump output to maintain a constant pressure and flow. in Neutral
This output varies according to demand. Position
Open Center
Figure 13. Spool Valves (Closed Center)
Spool Valve
in Neutral The closed center valve (Fig. 13) is used with variable
Position displacement pumps. The flow is completely shut off in
the neutral position, causing the pump stroke to adjust to
zero flow. The flow stops, but the pump maintains a static
Figure 12. Spool Valves (Open Center)
pressure up to the valve.
Hydraulic Motors
Figure 14. Gerotor Type Hydraulic Motor Closed Center Load Sensing Systems
Three Systems (Flow and Pressure Compensating)
Fitting these components together and installing a motor, The closed center flow compensated system is a vari-
we have one of the three types of systems: open center, ation of the pressure compensated system, designed
closed center (pressure compensated) and closed center primarily for more efficient operation and the generation
load sensing (flow and pressure compensated). of less heat. It works on the principle of maintaining a
constant pressure drop from the pump to the work port of
Open Center Systems the selector valve. Any variation in demand at the motor
In an open center system, the hydraulic pump puts out a will cause a change in flow. The system senses this
constant flow. If the pump puts out more oil than the motor change in flow due to the change in pressure drop across
can use, a portion of the oil must be bypassed around the the valve, and causes the pump to compensate by
motor. When the oil is bypassed around a loop and does varying the pump flow. No restrictor is used in the
no work, the energy put into it by the pump turns into heat. pressure line and no oil is bypassed.
300C-JD 10
05-02
Operation and Maintenance—Pump
Engage PTO Clutch slowly and smoothly. Avoid After spraying adjustments are made, close boom shut-
sudden starts and fast clutching that can damage the off valve to discontinue spraying.
drive section of the Pump.
On belt-drive models, check belt tension daily or before
Controlling the Flow
each use.
Two flow control valves are used - one in the agitation line
and one in the line leading to the boom or spray gun. This
permits controlling agitation flow independently of nozzle
Flush Pump After Use
One of the most common causes for faulty pump
flow.
performance is “gumming” or corrosion inside the pump.
Flush the pump and entire system with a solution that
To Adjust For Spraying will chemically neutralize the liquid pumped. Mix
To adjust sprayer (regardless of power source - PTO, belt according to manufacturer’s directions. This will dissolve
or pulley) follow these steps: most residue remaining in the pump, leaving the inside
of the pump clean for the next use.
1. Prime Pump with all valves open.
2. Close Control Valve and Agitation Line Valve; then, To Prevent Corrosion
open the Boom Shut–Off Valve. After cleaning the pump as directed above, flush it with
a permanent type automotive antifreeze containing a
3. With the Pump running, open the Control Valve until rust inhibitor. Use a 50-50 solution, half antifreeze and
Pressure Gauge indicates desired spraying half water, or fill pump with FLUID FILM and then drain
pressure. it. A protective coating of FLUID FILM will remain on
the inner pump surfaces. Save the excess FLUID FILM
4. Open the Agitation Line Valve until sufficient for the next application. Plug the ports to keep out air
agitation is observed. Then, if spraying pressure during storage. For shor t periods of idleness,
drops, readjust the Control Valve to restore desired noncorrosive liquids may be left in the Pump, but air
pressure. must be kept out. Plug the ports or seal the port
connections.
5. Make sure flow is uniform from all nozzles.
Troubleshooting (Pump)
Low Pump Not Primed Remove topmost Vent Plug from the face of the
Discharge Pump and run Pump to expel trapped air (See
Installation Instructions).
Blocked or clogged Line Strainer. Inspect Line Strainer and clear any debris from the
screen.
Undersize Suction Line or collapsed hose. The Suction Line should be the same diameter as
the Inlet Port or larger.
Impeller eye wear. Remove Volute (Front Cover) and inspect the
Impeller. If excessive wear is detected, replace
the Impeller.
300C-JD
11 05-02
Operation—Motor
Open Center Systems— All Models 3. Prime the Centrifugal Pump with all valves open
Adjusting Centrifugal Pump Output (See Plumbing Installation and Figure 1, Centrifugal
Plumbing Hook-Up).
1. Open the Bypass Adjustment Screw 2-1/2 turns
from fully closed. Turn the Bypass Screw in to 4. Close the Agitation Line Valve and keep the Control
achieve the flow for the desired gpm and psi. Valve and the Boom Shut-Off Valve open. Note
the spray pressure.
HM1C motors have a Bypass Screw set 1-1/2 turns 5. Open the agitation line valve until you have desired
from fully closed at the factory. HM4C motors have circulation in the tank. Recheck the spray pressure.
the Bypass Screw fully closed from the factory. If it is too low, close down the agitation line valve
until the desired spray pressure is reached. If the
2. Start the tractor. Leave the directional valve in the spray pressure is too high, throttle the centrifugal
neutral position and allow hydraulic oil to circulate pump by closing down the control valve.
for approximately 10 to 15 minutes or until
adequately warmed.
Closed Center (Pressure Compensated) — B. To install — tap the Orifice in from the large end
HM4C models only of the Adapter. The Orifice is seated when a
On a pressure compensated system, the amount of oil that “snap” sound is heard.
is allowed to flow through the Hydraulic Motor is regulated
by a metering orifice in the Pressure Port Adapter. Three Adjusting Centrifugal Pump Output
different sizes of orifices are supplied with the HM4C
Model Pumps to allow flexibility in the flow required for 1. Open the Bypass Adjusting Screw in the Hydraulic
individual sprayer needs. The smallest of the orifices is Motor three (3) turns.
installed in the Port Adapter at the factory.
2. Start the tractor and allow the hydraulic oil to circulate
The smaller the orifice, the less hydraulic oil goes through for approximately 10 to 15 minutes or until adequately
the motor, so the Pump will run slower and the flow of liquid warmed.
pumped and the spray pressure will also be less. As the
hydraulic oil flow is increased (by installing a larger orifice), 3. Close and lock down the Bypass Adjusting Screw in
the amount of liquid being pumped and the spray pressure the Hydraulic Motor.
is also increased.
4. Prime the Centrifugal Pump with all valves open (See
Installing and Removing Metering Orifice the installation instructions and system configuration
diagram).
Never use your hand to check the condition of hydraulic 5. Close the Agitation Line Valve and the Control Valve;
lines or hoses. If hydraulic fluid penetrates the skin, get then, open the Boom Shut Off Valve.
medical attention immediately. Failure to get proper
medical attention may result in loss of limb or life. The 6. With the pump running, open the Control Valve until
safest way to check hydraulic lines is by holding a piece the Pressure Gauge indicates the desired spraying
of cardboard next to the hydraulic line or hose. pressure.
1. Shut off the hydraulic system. 7. Open the Agitation Live Valve until sufficient agitation
is observed. Then, if spray pressure drops, readjust
2. Disconnect the line to the Pressure Port of the the Control Valve to restore the desired pressure.
Hydraulic Motor.
8. If a sufficient boom pressure cannot be attained,
3. Remove the adapter from the Motor using a install the #2 size Orifice and repeat the above steps.
1-1/16" wrench.
9. If a sufficient boom pressure cannot be attained with
4. Make sure the O-ring is on the Metering Orifice the #2 size Orifice, install the #3 size Orifice and
before installing into port adapter. repeat Steps 5 through 7.
5. The Orifice is removed or installed in the Port 10. If a sufficient boom pressure cannot be attained with
Adapter by tapping either in or out of the Adapter. the #3 size Orifice, remov the Orifice and repeat Steps
5 through 7.
A. To remove — tap the orifice out from the small
end of the Adapter.
300C-JD 12
05-02
Closed Center (Load Sensing) — All 5. Prime the Centrifugal Pump with all valves open (See
Models Plumbing Installation and Figure 1, Centrifugal
Many tractors are being introduced with load sensing Plumbing Hook-Up).
systems (also referred to as flow and pressure
compensated systems) which simplify system setup and 6. Close the Agitation Line Valve and open the Control
eliminate many of the problems associated with using the Valve and the Boom Shut-off Valve.
wrong size Pump Motors on a given hydraulic system.
Usually, any of the PM9300HMC Models may be used on
7. Slowly adjust the tractor Hydraulic Flow Control Valve
this type of system, provided the hydraulic system
until the desired boom pressure is attained.
produces sufficient oil flow for the Hydraulic Motor
being used.
8. Open the Agitation Line Valve until sufficient agitation
is observed. Then, if spray pressure drops, readjust
This system maintains a constant flow of hydraulic oil for
the tractor Hydraulic Flow Control Valve to restore to
a given pressure drop. The flow is adjustable with a Flow
the desired pressure.
Control Valve installed in the hydraulic system (Such as
the Tortoise/Hare control on John Deere tractors). Because
this system has adjustable flow, there is no need to Flush Pump After Use
One of the most common causes for faulty pump
bypass hydraulic oil as in an Open Center System, or to
performance is “gumming” or corrosion inside the pump.
restrict the flow with orifices as in a Closed Center
Flush the Pump and entire system with a solution that
Pressure Compensated System.
will chemically neutralize the liquid pumped. Mix
Adjusting Centrifugal Pump Output To Prevent Corrosion
1. Make sure the orifice from the pressure port adapter After cleaning the Pump as directed above, flush it with
of the hydraulic motor has been removed (HM4C a permanent type automobile antifreeze containing a
model only). rust inhibitor. Use a 50-50 solution, half antifreeze and
2. Close and lock down the Bypass Adjusting Screw in half water, or fill the pump with FLUID FILM and then
the Hydraulic Motor. drain it. A protective coating of FLUID FILM will remain
on the inner pump surfaces. Save the excess FLUID
3. Set the tractor Hydraulic Flow Control Valve for FILM for the next application. Plug the ports to keep out
minimum hydraulic oil flow to the remote outlet (Tortoise air during storage. For short periods of idleness, noncor-
position). rosive liquids may be left in the pump, but air must be
kept out. Plug the ports or seal the port connections.
4. Start the tractor and allow the hydraulic oil to circulate
for approximately 10 to 15 minutes or until adequately
warmed.
If the proper Hydraulic Pump has been selected performance is unsatisfactory or the hydraulic system
according to the manufacturer's recommendations, and generates excessive heat, etc. refer to the following
the unit has been correctly plumbed into the hydraulic troubleshooting guide for possible problems and
system, operation should be satisfactory. If spraying solutions.
Symptom Probable Cause(s) Corrective Action
Low discharge. Pump is not primed. Remove topmost Vent Plug from the face of the Pump and run
the Pump to expel trapped air (See Installation Instructions).
Air leaks in Suction Line. Inspect and reseal the Suction Line fittings.
Blocked or clogged Line Strainer. Inspect the Line Strainer and remove any debris from the screen.
Impeller plugged. Inspect Impeller and remove obstruction.
Undersized Suction Line or collapsed hose. The Suction Line should be the same diameter as the Inlet Port
of the Pump or larger.
Improperly sized Hydraulic Motor. Refer to the Pump Selection Guide to determine the proper size
Hydraulic Motor for your hydraulic system.
Bypass Adjustment Screw not properly set. Adjust the Bypass Screw on the side of the Hydraulic Motor in,
until the desired output is attained.
Impeller Eye wear. Remove Volute (Front Cover) and inspect the Impeller. If
excessive wear is detected, replace the Impeller.
Hydraulic System Improperly sized Hydraulic Motor. Consult your dealer to determine the proper size Hydraulic Motor
overheating. for your hydraulic system.
Bypass Adjustment Screw is set to bypass too Close the Bypass Adjustment Screw on the side of the Hydraulic
much oil Motor to lessen the amount of oil being bypassed.
Improper Metering Orifice installed in the Install the proper size Metering Orifice.
pressure port.
Insufficient hydraulic hose size. Check the Hydraulic Hose size. The Hydraulic Hose should be
be at least 1/2''. For large open-center systems 3/4''.
300C-JD
13 05-02
Repair Instructions—Pump
Figure 15
Recommended Repair Tools
Instructions following in italics describe procedures Figure 17 shows PM9000CO gear flange; the same
for the polypropylene centrifugal pumps, when differ- general procedure applies for the other pumps.
ent than the cast iron pumps.
1. Remove the four Casing Cap Screws with 9/16" box
Pump Seal Removal
end wrench. Tap the Pump Casing on discharge port 1. Lightly lubricate the Shaft for easier removal of the
with rubber hammer, if necessary, to break it loose Seal. Using two screwdrivers positioned opposite
from the Mounting Flange. Check inside of Pump each other, pry the rotary portion of the Seal from the
Casing including suction port. If badly eroded (or Shaft (See Figure 18).
damaged ), Pump Casing should be replaced. Re-
move O-ring and discard. O-ring should always be
replaced. (Using a 1/2" wrench, remove the six bolts
from the front. Also remove the 5/16" screw from the
rear near the outlet port.)
2. To remove the Impeller Nut, clamp the Flange in a
vise and insert a large screwdriver or file (at least 10"
[254 mm] long) into the Impeller Vanes to prevent the
Impeller from turning when loosening the nut. Use a
socket wrench (3/4" for Series PM9000CO or 5/8" for Figure 18
Series PM9200C and PM9400C) to remove the Pump Seal Removal
Impeller Nut by turning it counterclockwise. (See
Figure 16) (Use 7/8" deep socket wrench to remove
2. (Remove Plastic Back Cover Flange; then, tap the
plastic seal nut, then 9/16" deep socket to remove the
Seal out from the back with a hammer and screw-
Metal Jam Nut, Rubber Gasket and Washer.)
driver.)
3. Remove Stationary Seat and Boot by prying out with
two small screwdrivers in manner similar to Impeller
removal.
2. Remove the four Gear Case Cap Screws with On 1000 rpm models, Sun Gear must first be
9/16" socket wrench. removed with wheel puller. Exposed Retaining Ring
must also be removed.
3. Remove Mounting Flange Adapter from Gear
Housing. 5. Place Mounting Flange Adapter in an arbor press
with the shaft end up. Press out the Shaft and
Bearing Assembly (See Figure 20).
Special attention should be exercised when working
with retaining rings. Always wear safety goggles 6. Check the Bearing for wear or damage. It should
when working with spring or tension loaded turn smoothly and easily. Do not wash the bearing.
fasteners or devices.
300C-JD
15 05-02
12. Wash and inspect the parts. Examine the teeth of
Driver Gears for excessive wear or damage. Also
check to see that the Inner Bearing Race surfaces
and Nylon Thrust Washers are not worn or scored.
13. Remove Cushion Bumpers with needle nose pliers or
a small screwdriver, then remove Fixed Internal Gear
by hooking fingers at bottom and pulling up (See
Figure 23).
Figure 20
15. With a flat blade screwdriver, pry the Oil Seal from
the Gearcase. Removing in this manner will
damage the Seal and make it unsuitable for reuse.
10. Wash and then examine the teeth of the Shaft 16. Remove the Main Bearing Retaining Ring with
Pinion Gear or Sun Gear for excessive wear or pliers ; then, remove the Slinger Ring.
damage. Also make sure that sealing area of Shaft
is smooth, not worn or pitted. In most cases, the 17. Place the remainder of the Gear Case Assembly
sealing area can be polished smooth. In the area in the press, face down (See Figure 24). Press out
where the Rubber Driving Ring contacts the Shaft, the Driver Hub.
some roughness is required around the Shaft to
prevent seal slippage.
Figure 22
Figure 25
300C-JD 16
05-02
7. Insert the Pump Shaft into the Bearing and place it
20. Check the Main Bearing for roughness or damage. It
in a press with the Bearing supported (See Figure
should turn smoothly and easily.
27). For 540 rpm models, press down until the Gear
touches the Bearing; for 1000 rpm models, press
Gear Drive Unit Reassembly
until it is between the Retaining Ring grooves. Install
the Crescent Retaining Rings by starting it in the
groove and pressing on with flat of screwdriver (one
Before reassembling the Gear Drive Unit, all parts ring on 540 rpm models, two rings on 1000 rpm
should be examined, and parts being reused should models).
be clean and free of old oil. Do not wash the Main
Bearing.
3. Slip the Belt off of the Large Pulley. 4. Press out the Bearing using an arbor press.
4. Wrap the new Belt around the Small Pulley and on 5. To reassemble, reverse the procedure.
the inside of the Idler Pulley.
Pedestal Bearing Replacement
5. Place a 15/16" socket onto the head of the Idler
Arm Bolt and apply tension in a counterclockwise 1. Remove the Belt.
direction.
2. Remove the Large Pulley Retaining Ring and
6. Slip the Belt around the Large Pulley, insuring that Pulley.
the grooves on the Pulleys match the grooves on
the Belt.
For Quick Coupled Models, remove the Outer
Belt Alignment and Tension Keeper Ring and Keeper Balls.
Figure 30
300C-JD 18
05-02
Repair Instructions—Hydraulic Motor
Figure 32
300C-JD
19 05-02
Hydraulic Motor Shaft Disassembly and To Install Shaft Bearing
Repair 1. Over the threaded end of the Shaft, install the
Spacer Ring and the Ball Bearing.
Special attention should be exercised when working
with retaining rings. Always wear safety goggles Special attention should be exercised when working
when working with spring or tension loaded with retaining rings. Always wear safety goggles
fasteners or devices. when working with spring or tension loaded
fasteners or devices.
1. Remove Large Retaining Ring from Shaft with a
screwdriver. Remove Thrust Bearing Assembly from 2. Insert the Shaft (threaded end down) into the arbor
Shaft (includes the Thrust Bearing and two Thrust press fixture. Place the two support bars opposite
Bearing Races) and the Seal Spacer. each other and between the Bearing and the fixture.
Place on an arbor press and carefully press the
2. Remove the small Retaining Ring next to the shaft Shaft down allowing just enough room for the
Ball Bearing. Retaining Ring next to the Bearing to be installed.
3. To remove the Bearing from the Shaft, place the
Shaft (threaded end up) in the arbor press fixture.
Place the two support bars provided in the repair Make sure the Spacer Ring between the Seal and
kit opposite each other and between the Seal on Bearing is free floating (not binding).
the Shaft and the arbor press fixture. Using an arbor
press, press the Shaft through the Bearing, Seal
Spacer and Seal (See Figure 34). Should the Main Needle Bearings in the Hydraulic
4. Inspect the sealing area of the Shaft for wear. Inspect Motor need replacement, a new Body and/or End
other Shaft Assembly components for wear and re- Plate, with the Main Bearing already installed, must
place if necessary. be used. If this occurs, check other internal parts of
the Motor for damage and wear.
Figure 34 Figure 35
To Install New Shaft Seal 2. On arbor press, place Body on arbor press fixture.
1. The sealing lips on a new Seal must be expanded
to fit on the Shaft. Press Seal onto large end of
Shaft with Seal lip facing out. Do not push Seal past Make sure the surface edge of the fixture is smooth
keyway on Shaft. and clean.
An un-threaded piece of pipe (1" [25.4 mm] dia. x 4" [101.6
2. Once Seal lip has been expanded, remove the Seal
from the Shaft. mm] high) is needed to support the Outer Bearing Race on
the Shaft Ball Bearing. Place this pipe over the Shaft and
3. With the Seal lip facing the large end of the Shaft, press Shaft Assembly down until Retaining Ring can be
slide the Seal over the threaded end of Shaft and installed in its groove in the bearing bore of the motor body
gently push onto the raised area of the Shaft, (See Figure 36).
stopping approximately 1/4" from the large
Retaining Ring groove.
4. Over the large end of the Shaft, install the Seal
Spacer, Thrust Bearing Race, Thrust Bearing,
second Thrust Bearing Race and the large
Retaining Ring.
Figure 36
300C-JD 20
05-02
Reassembly of Remaining Hydraulic Motor 10. Install four Socket Head Cap Screws in Motor End
Parts Plate and, using a 1/4" allen wrench, tighten Cap
Screws in a crisscross pattern to approximately 15
1. Place Motor Body in a vise with large end of Shaft
foot pounds [2.07 Nm] of torque.
facing up.
11. Install the Thread Seal Gasket on the Bypass
2. Install the O-ring in the Body.
Adjusting Screw. Put the Gasket on from the slotted
end and turn until four threads on the screw are
3. Install the Roll Pin on the Shaft. Place the Inner
showing. Install the Washer and the Nut. Install
Gear of the Gerotor onto the Shaft making sure
Bypass Adjusting Screw in the Motor End Plate.
Gerotor slot lines up with the Key in the Shaft.
A. For Closed Center Hydraulic Systems, turn the
Bypass Adjusting Screw in until it bottoms out
The Woodruff Key can slide up behind the Inner Gear in the End Plate. Tighten Nut down with 9/16"
of the Gerotor when the Gear is installed. Make sure box end wrench.
the Key is visible in the slot after the Gear is in place.
B. For Open Center Hydraulic Systems, turn the
4. Install the outer portion of the Gerotor, making sure
Bypass Adjusting Screw in until it bottoms out
the Gerotor is centered within the o-ring groove on
in the End Plate; then turn back out 11⁄2 full
the Body.
turns. Holding the Bypass Adjusting Screw with
5. Install the Gerotor Housing, making sure the Pins a screwdriver, tighten Nut. (Motor will then have
in the Gerotor Housing line up with their respective to be readjusted to tractor system.)
holes in the Body.
12. Replace O-ring in both Port Adapters.
6. Lightly lubricate the area between the Inner and
Outer Gerotor and the Outer Gerotor and Gerotor 13. Install Pressure Port Adapter and Tank Port Adapter
Housing with hydraulic oil or mineral oil. back onto the Motor. (For ease of installation, tighten
the Pressure Port Adapter first, then the Tank Port
7. For units with a Motor End Plate Plug, remove Adapter.)
Retaining Ring with small retaining ring pliers. Tap
Plug out from the inside of the End Plate. Remove 14. Remove Hydraulic Motor from the vise. Turn Shaft
the O-ring, inspect and replace if necessary. by hand to check for binding.
8. Install O-ring on the Motor End Plate. 15. Install Slinger Ring over Motor Shaft.
9. Place End Plate on Gerotor Housing, making sure 16. Install Motor into Pump Mounting Flange. Insert four
holes in End Plate line up with Pins in the Gerotor Hex Head Bolts and tighten securely.
Housing.
Performance Graphs
20 20
1 1
10 10
0 0
0 10 20 30 40 50 60 70 80 90 100 0 0
0 20 40 60 80 100 120
GPM GPM
300C-JD
21 05-02
Performance Graphs
PM9402C1000 PM9402C540
L/min L/min
0 50 100 150 200 250 300 0 50 100 150 200 250 300
100 100
P 60 4 B 60
P 500 RPM 4 B
S A S 50
800 RPM 450 RPM A
I
3 R I 3
40 40 R
2 30 2
20 20
1 1
10
0 0 0 0
0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80
GPM GPM
PM9403C1000 PM9403C540
PM9403C1000 L/min
L/min
L/min
0 100 200 300 400 500
0 100 200 300 400 500 120
120 8
8
7
100 1000 RPM 7 100 600 RPM
6 6
80 900 RPM 80 540 RPM
5 5
P B P 500 RPM B
S 60 800 RPM 4 A S A
60 4
I R I 450 RPM
3 R
40 3
40
2
20 2
1
20
0 1
0
0 20 40 60 80 100 120 140 0 0
0 20 40 60 80 100 120 140
GPM
GPM
300C-JD 22
05-02
Performance Graphs
PM9302CHM1C PM9302CHM4C
L/min L/min
0 50 100 150 200 250 300 350 0 50 100 150 200 250 300
140 100
9 90
13 GPM 7 GPM 6
120 8
12 GPM 80
7 5
100 11 GPM 70 6 GPM
P 6 B P 60 4
B
S 80 A S A
5 50 5 GPM R
I R I
60 3
4 40
3 30 2
40
2 20
20 1
1 10
0 0 0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90
GPM GPM
PM9303CHM1C PM9303CHM4C
L/min L/min
0 50 100 150 200 250 300 350 400 450 0 50 100 150 200 250 300 350
140 100
9 90
13 GPM 7 GPM 6
120 8
12 GPM 80
5
100 11 GPM 7 70 6 GPM
6 60 4
P 80 B P B
5A S 50 5 GPM A
S 3
60 I 40 R
I 4R
3 30 2
40
2 20
1
20 10
1
0 0 0 0
0 20 40 60 80 100 120 0 20 40 60 80 100 120
GPM GPM
PM9304CHM1C PM9304CHM5C
L/min L/min
0 100 200 300 400 500 600 700 800 900 0 100 200 300 400 500 600 700 800 900
120 8 100
13 GPM 90
7 15 GPM 6
100 12 GPM
80 14 GPM
6 5
70 13 GPM
80
11 GPM
5 60 4
P B P B
S 60 50
4A S A
3
I R I 40 R
3
40
30 2
2
20
20 1
1 10
0 0 0 0
0 50 100 150 200 250 0 50 100 150 200 250
GPM GPM
300C-JD
23 05-02
Performance Graphs
PM9305CHM3C
PM9305CHM3C
L/min
L/min
0 100 200 300 400 500 600 700
160 11
10
140 19 GPM
18 GPM 9
120 17 GPM
8
P 100 7
B
S 6 A
I 80
R
5
60 4
3
40
2
20
1
0 0
0 20 40 60 80 100 120 140 160 180 200
GPM
Performance Charts
900 74 73 67 60 51 23
1000 76 76 76 75 68 62 52 22
450 61 54 45 21
9204C 500 67 64 60 51 25
540 540 71 71 68 63 54 25
600 76 76 75 74 70 63 53 23
450 107 99 86 50
9203C 500 121 116 106 93 76 42
540 540 129 127 120 111 98 80 50
600 140 138 135 130 121 112 94 73 40
300C-JD 24
05-02
Performance Charts
10 psi 20 psi 40 psi 60 psi 80 psi 100 psi 120 psi 140 psi 160 psi
RPM GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP GPM HP
PM9203C
2400 80 1.9 65 1.8 26 1.3
3600 105 5.3 105 5.3 92 5 50 3.7
4200 120 7.9 115 7.7 98 7.1 56 5.3
5000 140 12.6 138 12.6 130 12.2 118 11.6 88 9.9 45 7.2
5500 140 14.9 138 14.9 135 15.2 130 15.2 118 14.4 90 12.5 60 9.8
6000 140 17.1 140 17.5 140 18 135 18.2 130 18.8 125 18.2 100 16.3 80 13.5
Hydraulic GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at
Flow 10 psi 20 psi 30 psi 40 psi 50 psi 60 psi 70 psi 80 psi 90 psi 100 psi 110 psi 120 psi 130 psi
PM9303C
5 GPM 84 76 66 52 34
HM4C 6 GPM 99 90 84 78 67 43 25
7 GPM 110 97 92 86 77 64 48 38 14
Hydraulic GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at GPM at
Flow 10 psi 20 psi 30 psi 40 psi 50 psi 60 psi 70 psi 80 psi 90 psi 100 psi 110 psi
11 GPM 210 203 178 140 89 44
PM9304C
300C-JD
25 05-02
Parts List for PM9006CO, PM9008CO, & PM9016CO
Figure 37
300C-JD 26
05-02
Parts List for PM9402C & PM9403C
22
17
16
15 11
12
14
13
19
18
10 8 5
6
7
6
20
21
4
5
2 3 9
Figure 38 1
300C-JD
27 05-02
Parts List for PM9203C
5
4
9
3
2
Figure 39
300C-JD 28
05-02
Parts List for PM9203CR
5
4
9
3
1
Figure 40
300C-JD
29 05-02
Parts List for PM9303PHM4C
Figure 41
300C-JD 30
05-02
Parts List for PM9302CHM1C, PM9302CHM4C, PM9303CHM1C & PM9303CHM4C
Figure 42
300C-JD
31 05-02
Parts List for PM9304CHM1C & PM9304CHM5C
Figure 43
300C-JD 32
05-02
Parts List for PM9305HM3C
9
8
7
6
2 5
4
32
31
25
1
25
22 29
18
16 20
1 14
13 When ordering parts, give Quantity, Part Number,
Description and the Complete Model Number. Reference
numbers are used to identify parts in the drawing and
Figure 44 are not to be used as Order Numbers.
Ref. Part
No. Number Description Qty.
1 PM24060007 Drain/Vent Plug 4
2 PM01529200CM Pump Casing (Includes 1
Stainless Steel Wear Ring)
4 PM22530002 Impeller Nut 1
5 PM22700071 Washer 1
6 PM04039200P1 Impeller 1
7 PM17000100 Rubber Gasket 1
8 PM17200180 O-ring 1
9 PM21200009 Mechanical Seal (Viton) 1
13 PM18100014 Retaining Ring 1
14 PM20000010 Ball Bearing 1
16 PM21040005 Shaft Seal 1
18 PM20290014 Thrust Bearing Assy. 1
(1) Thrust Bearing
(2) Thrust Brg. Races
20 PM05142500 Shaft 1
22 PM16100055 Key 1
25 PM17200110 O-ring 2
29 PM39000024 Gerotor 1
31 PM32200029 Bypass Adjusting Screw 1
32 PM17000047 Gasket 1
300C-JD
33 05-02
Notes
300C-JD 34
05-02
Notes
300C-JD
35 05-02
Printed in USA
300C-JD 36
05-02