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1. Then inspect both housings for any contaminates or visual defects With a clean towel or rag wipe the housings clean 3 The gears have retaining ring grooves on the output side and a seal lip on the input side Install the gears into the housing half with the input side of the gear facing down or to where the engine adapter would be attached see Figure F Tip Apply a small coat of oil to the outside of the bearing to allow gear and bearing to slide into housing easier 4 Place approximately a 1 8 bead of Loctite 587 or equivalent sealant along the sealing surface of the input housing half Applying too much sealant to sealing surfaces may cause excessive sealant to break loose inside gear box and damage gears bearings or splines 5 Place the output housing half together with the input housing Both housings must be orientated in the same direction for the dowel pin holes to line up properly see Figure G INPUT SIDE DOWN SEALANT ON THIS SURFACE Figure F Phone 608 365 2563 10 Fax 608 365 2182 6 Press in the two 2 dowel pins to insure proper Do not use sharp objects for pressing in alignment Evenly install and tighten the cap seals Press only on the outer edge of the seal to keep screws Refer to Table 1 see page 33 for proper from bending or damaging the seal casing torque specifications 8 To install the dipstick upright the gear box Apply 7 Turn over the assembled ge
2. Next Generation HYDRAULIC PUMP DRIVES Patent Pending SERVICE MANUAL Driven by DURST TABLE OF CONTENTS WARNINGS AND CAUTIONS ooooooooooc nenne rennen 1 MODEL IDENTIFICATION Nomenclature for Clutch Assemblies 0 00 cece cece cence eee nennen 2 Nomenclature tor Drive Plate Assemblies ocio ara ea 3 Nomenclature for Independent Input Assemblies oooooccoccococoooo 4 INSTALLATION INSTRUCTIONS Clutch A sea A sales seiten 6 Drive Plate Dive sorted 6 independent Shatt AAA een ern ee eeademaded 6 Mounting Procedure for Durst Pump Drives 2 2 2 22 am nn ae 7 Installing Hydraulic Pumps to Durst Pump Drives 4 a8 aa 7 REPAIR AND REBUILDING INSTRUCTIONS DisascemblyINGMUCHONG ves gt 60439050007 isla na aa ales ga ah E rear dba 8 9 Reassembiy INSWUCHONG sy occ di ii a 10 11 LUBRICATION AND OIL A ea ee tes ans ak ck wate ee A ate a ees 12 Oil Capacity for 6 Inch Gear Centers sent dl u ae ea os 13 Oil Capacity for 8 Inch Gear Centers 242 ums 2u0u sun rr rr AR 14 Oil Gapacity for 9 Inchi Gear Cemer idad pa dia ridad 14 Oil Capacity for 10 5 Inch Gear Centers 3 4422 accu 22 ida cid 15 Oil Capacity for 11 3 Inch Gear Centers 0 0 ccc ccc eee cece eee een e eens 15 PART NUMBER CHARTS 1PB06 Mod le Pump DING 24024244 iraire a ae aaa ua hen pr aeg 16 2PD06 Mod le Pump DING scr na anna 17 3rBNG Mod le Pump DIVE ri tl A rn er saad oe 18 2PD08 Module Pump Drive a aaa
3. 012016 BEARING 10 Complete Gear Box P N K12257 K12255 K12253 K12251 K12252 K12254 K12256 012042 SEAL B OUTPUT GEAR 4 012185 INPUT HOUSING 012186 OUTPUT HOUSING Input Output Ratio Gear A Gear B 1 39 Inc 012058 012050 1 31 Inc 012057 012051 1 16 Inc 012056 012052 1 1 012053 012053 1 16 Dec 012052 012056 1 31 Dec 012057 012051 1 39 Dec 012050 012058 25 Fax 608 365 2182 PUMP SPLINE ADAPTER The following chart lists all available spline adapters for the Durst pump drives The spline adapters can be purchased as either complete kits or individual components Complete Spline Pump Shaft Max Torque Spline Retaining Adapter Kit P N Size in Ibs K12072 SAEA 517 K12073 SAE B 1 852 K12074 SAE BB 2 987 K12075 SAE C 5 677 K12076 SAE CC 10 777 K12077 SAE D 15 057 K12078 SAE F 24 245 K12264 21T K12265 23T K12266 27T Spline Adapter Ring 9T 16 32 012014 012044 13T 16 32 012017 012044 15T 16 32 012018 012044 14T 12 24 012019 012044 17T 12 24 012020 012044 13T 8 16 012021 012044 15T 8 16 012022 012304 21T 16 32 012261 012044 23T 16 32 012262 012044 271 16 32 012263 012044 PUMP SPLINE ADAPTER INSTALLATION INSTRUCTIONS RETAINING RING SPLINE ADAPTER Figure J 1 Install the first retaining ring into the furthest snap ring groove of desired gear see Figure K Note that the SAE F spline adapter requires a different retaining ring see chart 2 Inser
4. 2 50 Dia Keyed Shaft 004 2 25 Dia Keyed Shaft 005 29T 12 24 Shaft 006 20T 10 20 Shaft 007 15T 8 16 Shaft 008 Special Shaft 2PD06 1 32 D003 CCH CCH LS TL TR LL LR Model Ratio Increaser D Decreaser PUMP PAD OPTIONS A SAEA B SAEB PUMP SPLINE ADAPTER C SAE C A SAE A 9T 16 32 D SAE D B SAE B 13T 16 32 D2 SAE D 2 bolt BB SAE BB 151 16 32 E SAE E C SAE C 14T 12 24 F SAE F CC SAE CC 17T 12 24 D SAE D 13T 8 16 F SAE F 15T 8 16 21 21T 16 32 23 231 16 32 27 271 16 32 Phone 608 365 2563 4 Standard Assy N Non Standard V Vertical Inverted X Special L Dipstick on Left Side R Dipstick on Right Side N No Dipstick H Pad Mounted Horizontally V Pad Mounted Vertically Fax 608 365 2182 ABOUT YOUR NEW DURST PUMP DRIVE The New Durst pump drives incorporate some of the features from both the previous Terrell and Hub City designs as well as many new and simplistic features The Durst pump drive now incorporates class 10 spur gears that run on heavy duty ball bearings Because ball bearings do not require shimming the assembly of a pump drive is drastically simplified This also allows for the bearing to be contained within the housing halves The key feature about this is that any adapter can be changed out without disturbing the gears or bearings in the gear box This also allows for the box
5. 19 SPENS Module PUMD DIVE susanne teste reine ei 20 4PD08 Module Pimp Dive cierras dad rita AA nad 21 4PD09 Module PUMP Drive siria aa ad A a a a ana a erh in 22 2PD 40 Module Pump DING 2 024504 2u02204 apine ande ed nee area nee 23 SPD 1G Mod le Pump Dive esos ir ann are 24 A4PD11 Module Pimp Drive coords vi ee ADA enia eiia 25 Pump Spline Adapter 2 2 22 ee a een dass BES aaa 26 P mp Pad dale 22 24 5er SA 27 PIPUC ONO NUNS coed zarte te datada dia 28 Clutch Housings and Engine Adapters sesos tee 29 Drive PROPIOS sera rasen mui pis dias aa Eaa Eaa a aa nds Fee Ba a au Ares 30 Clute MODINE ieia ne ee II aE eh E ar ds Pare aes cee ee 31 32 GENERAL INFORMATION TOIS Needed Yen 225 aan Had E 33 PA ee a heine 33 A A En N E E 33 WARNEN en nee ws E A eee oleae 34 IMPORTANT INFORMATION Please Read Carefully Upon receipt of product immediately inspect for any indication of rough handling or damage in transit This includes but is not limited to scuffed paint broken or damaged containers broken or cracked housings bent shafts metal deformation or shift in alignment of components Any evidence of damage or missing parts should be reported immediately to the carrier and a claim entered AACAUTION All units are shipped without oil DO NOT OPERATE until unit has been filled to the proper level with the specified oil grade rn Failure will occur if bearings and gears are not properly lubricated Refer to Lubrication and Oil Filling In
6. 40 Inc 1 34 Inc 1 23 Inc 1 1 1 23 Dec 1 34 Dec 1 40 Dec Oil Capacity 3PD08 Inverted Mounting Ratio 1 40 Inc 1 34 Inc 1 23 Inc 1 1 1 23 Dec 1 34 Dec 1 40 Dec Oil Capacity 3 43 Qts 3 25 Liters 3 25 Qts 3 08 Liters 3 43 Qts 3 25 Liters Note All oil capacities are approximate Refer to Lubrication and Oil Filling Instructions when adding or changing oil Phone 608 365 2563 Fax 608 365 2182 10 5 INCH GEAR CENTERS 2PD10 Normal Mounting Ratio 1 38 Inc 1 29 Inc 1 21 Inc 1 1 1 21 Dec 1 29 Dec 1 38 Dec Oil Capacity 4 50 Qts 4 25 Liters 5 25 Qts 4 97 Liters 6 00 Qts 5 68 Liters 5 25 Qts 4 97 Liters 5 25 Qts 4 97 Liters 3PD10 Normal Mounting Ratio 1 38 Inc 1 29 Inc 1 21 Inc 1 1 1 21 Dec 1 29 Dec 1 38 Dec Oil Capacity 10 50 Qts 9 94 Liters 8 25 Qts 7 80 Liters 11 3 INCH GEAR CENTERS 4PD11 Normal Mounting Ratio 1 39 Inc 1 31 Inc 1 16 Inc 1 1 1 16 Dec 1 31 Dec 1 39 Dec Oil Capacity 7 25 Qts 6 86 Liters 7 50 Qts 7 10 Liters 6 25 Qts 5 91 Liters 2PD10 Vertical Mounting Ratio 1 38 Inc 1 29 Inc 1 21 Inc 1 1 1 21 Dec 1 29 Dec 1 38 Dec Oil Capacity 4 50 Qts 4 25 Liters 4 50 Qts 4 25 Liters 4 50 Qts 4 25 Liters 3PD10 Inverted Mounting Ratio 1 38 Inc 1 29 Inc 1 21 Inc 1 1 1 21 Dec 1 29 Dec 1 3
7. LS 2PD08 1 40D 343 CCH DDH RS ok 4PD08 4PD09 4PD11 CLUTCH STAND OFF CLUTCH HOUSING 1 SP214 1 00 in 1 SAE 1 2 SP211 1 56 in 2 SAE 2 3 Not Available 3 SAE 3 4 0111 1 56 in NN 2 12 in PILOT BEARING 1 3 94 Dia for SP214 2 3 15 Dia for SP214 3 2 83 Dia all others 2PD06 1 32 D 343 CCH CCH LS 4PD08 1 1 111 CCV CCH CCH CCH LS TE TR LESER Model Standard Assy N Non Standard V Vertical Inverted X Special L Dipstick on Left Side Ratio Increaser D Decreaser PUMP PAD OPTIONS A SAEA D2 SAED 2 bolt PUMP SPLINE ADAPTER ld et A SAE A 9T 16 32 D SAE D 13T 8 16 En C SAEC F SAEF B SAE B 131 16 32 F SAE F 151 8 16 LPa Mounted Horizontally Beene BB SAE BB 15T 16 32 21 217 16 32 V Pad Mounted Vertically C SAE C 147 12 24 23 231 16 32 CC SAE CC 17T 12 24 27 271 16 32 Phone 608 365 2563 2 Fax 608 365 2182 NOMENCLATURE FOR DRIVE PLATE ASSEMBLIES 2PD06 2PD08 2PD10 1PDO6 1 321 D33 CCH LS 2PD08 1 40D N23 CCH DDH RS L R 4PD08 4PD09 4PD11 ENGINE ADAPTER HOUSING 1 SAE 1 2 SAE 2 3 SAE 3 4 SAE 4 D With Drive Plate N No Drive Plate Shaft ONLY 4PD08 1 1 D1
8. Note Dipstick P N K12220 1 40 Inc 012107 012100 012307 is not provided in gear box kit but is required in 3 a E oa all normal mounted installations It can be installed either K12216 1 18 ne 012105 012102 left or right side Two expansion plugs P N 012326 are K12214 14 012104 012104 not provided in gear box kit but are required in all K12215 1 18 Dec 012102 012105 vertical installations For replacement gears with bearings K12410 1 25 Dec 012408 012409 assembled order gear as a kit with a K number i e To K12217 1 32 Dec 012101 012106 order a 012104 gear with 2 012015 bearings order iene I oe a eu K12223 1 57 Dec 012098 012109 K12225 1 67 Dec 012097 012110 Phone 608 365 2563 Fax 608 365 2182 3PD06 MODULE PUMP DRIVE J84 DOWEL PIN 2 SEE NOTE FOR DIPSTICK AND PLUG K38 INVERTED OIL LEVEL PLUG 012236 MAGNETIC DRAIN PLUG The following chart lists all of the complete assembly part numbers with the prefix of K All of the pump drive gear boxes can be purchased as a complete kit and will come fully assembled with all of the part numbers as shown in the above figure including the gears shown in the below table to create the desired ratio Note Dipstick P N 012308 is not provided in gear box kit but is required in all normal mounted installations It can be installed either left or right side Two expansion plugs P N 012326 are not provided in gear box kit but are required in all
9. inverted installations For replacement gears with bearings assembled order gear as a kit with a K number i e To order a 012105 gear with 2 012015 bearings order as K12105 Phone 608 365 2563 Complete Gear Box P N K12235 K12233 K12231 K12229 K12227 K12228 K12230 K12232 4400 101 VENT 012166 FITTING 012015 BEARING 8 A INPUT GEAR 012042 SEAL Ratio 1 52 Inc 1 36 Inc 1 29 Inc 1 17 Inc 1 1 1 17 Dec 1 29 Dec 1 36 Dec B OUTPUT GEAR 3 D70 WASHER 12 D1353 CAP SCREW 12 012169 INPUT HOUSING 012170 OUTPUT HOUSING Input Output Gear A Gear B 012111 012101 012110 012102 012109 012103 012107 012104 012105 012105 012104 012107 012103 012109 012102 012110 Fax 608 365 2182 2PD08 MODULE PUMP DRIVE J84 DOWEL PIN 2 012059 PLUG The following chart lists all of the complete assembly part numbers with the prefix of K All of the pump drive gear boxes can be purchased as a complete kit and will come fully assembled with all of the part numbers as shown in the above figure including the gears shown in the following table to create the desired ratio Note Dipstick P N 012260 is not provided in gear box kit but is required in all normal mounted installations It can be installed either left or right side Two expansion plugs P N 012326 are not provided in gear box kit but are required in all vertical installations For replacement gears with b
10. orientations will cause premature failure INSTALLATION OF HYDRAULIC PUMPS TO DURST PUMP DRIVES The pump pads on the Durst pump drives offer two or four bolt mountings which can be mounted vertically or horizontally to provide the customer a wide range of hydraulic pump mounting options 1 Lubricate the included o ring with oil and install it onto the hydraulic pump pilot Due to an internal oil lubrication system do NOT apply any grease or spline lubricant as this will contaminate the oil Phone 608 365 2563 2 Align the splines of the hydraulic pump to the spline adapter DO NOT use the hydraulic pump mounting bolts to seat the hydraulic pump onto the pump pad Refer to the hydraulic pump manufactures specification for proper bolt torques NOTE O rings must be replaced anytime the hydraulic pumps are removed from the gear box 7 Fax 608 365 2182 REPAIR amp REBUILDING INSTRUCTIONS DISASSEMBLY INSTRUCTIONS 1 Make certain that the power supply is disconnected before attempting to service or remove any components Lockout the power supply and tag it to prevent unexpected application of power 2 Drain oil while the unit is still warm Hot oil can cause severe burns Use extreme care when removing lubrication plugs and vents 3 Properly support the pump drive and remove all retaining bolts from the pump drive engine adapter then
11. 0 K12276 20T 10 20 1 790 012121 K12278 15T 8 16 1 545 012285 K12279 2 25 Dia w 0 500 keyway 2 225 012122 K12280 2 50 Dia w 0 625 keyway 2 325 012149 K12281 For SP214 Clutch N A 012190 K12282 For SP211 Clutch N A 012189 K12283 For 6111 Clutch N A 012188 K12284 For 6110 Clutch N A 012187 012045 RETAINING RING INPUT SHAFT 012043 EXPANSION PLUG 012046 O RING INPUT SHAFT INSTALLATION INSTRUCTIONS 1 Use fresh oil to lubricate all o rings prior to installation o RETAINING 2 Install 012046 o ring into shaft groove INPUT SHAFT RING 3 Insert shaft into the drive gear ofthe gear box until the shoulder contacts input gear EXPANSION 4 Install 012045 retaining ring onto shaft through the PLUG back side of the gear box i 5 Apply a thin coat of Loctite 609 or equivalent to the 0 D of the 012043 expansion plug before installation Phone 608 365 2563 28 Fax 608 365 2182 CLUTCH HOUSINGS amp ENGINE ADAPTERS 1723 115 INSPECTION COVER 4054 401 CAP SCREW 2 4006 108 WASHER 2 ENGINE ADAPTER D70 WASHER 8 S2810 1 CAP SCREW 8 CLUTCH HOUSING D70 WASHER 8 S2812 1 CAP SCREW 8 The following chart lists all available clutch housings and housings and engine adapters can be purchased as either engine adapters for the Durst pump drives The clutch complete kits or individual components Complete Engine SAE Engine Engine Mounting Engine Adapter Kit
12. 012083 D pump at 45 degrees K12071 F 012028 012133 012084 3 The E45 option allows for mounting an SAE E pump at 45 degrees B CAP SCREW 4 A PUMP PAD 012047 O RING PUMP PAD ADAPTER INSTALLATION INSTRUCTIONS 1 Use fresh oil to lubricate all o rings prior to 4 Install cap screws or stud and nut if applicable installation Torque bolts according to Table 1 see page 33 2 Install 012047 o ring onto pilot groove as shown Do not apply Loctite or any type of thread above locking material to pump pad screws 3 Place pump pad onto gear box and press down 5 The C o ring seals the hydraulic pump to the gear until the pump pad fully seats into gear box Due to box For installation instructions see Installation of the modular design pump pads can be installed either Hydraulic Pumps to Durst Pump Drives page 7 horizontally or vertically Phone 608 365 2563 27 Fax 608 365 2182 INPUT SHAFT OPTIONS The following chart lists all available input shaft replaced without affecting the pump pads However in options for the Durst pump drives The input shafts can some pump drive models the pump pad s overlap the be purchased as either complete kits or individual expansion plug This requires the pump pad s to be components In most cases the input shaft can be removed before replacing the input shaft Complete Input Shaft Max Torque Input Shaft Kit P N Description ft lb Shaft K12275 29T 12 24 2 325 01212
13. 1 CCV CCH CCH CCH LS MATA En 3PD06 3PD08 3PD10 3PD06 1 291 D22 CCH CCH CCH NS TELA WITH DRIVE PLATE 1 SAE 14 2 SAE 11 5 3 SAE 10 4 SAE 8 NO DRIVE PLATE 1 29T 12 24 Shaft 2 20T 10 20 Shaft 3 15T 8 16 Shaft 4 2 50 Dia Keyed Shaft 5 2 25 Dia Keyed Shaft 2PD06 1 32 DD11 CCH CCH LS Model Ratio Increaser D Decreaser PUMP PAD OPTIONS A SAEA B SAEB gt g PUMP SPLINE ADAPTER een A SAE A 9T 16 32 D SAE D 131 8 16 a B SAE B 13T 16 32 F SAE F 151 8 16 ER BB SAE BB 157 16 32 21 21T 16 32 C SAE C 14T 12 24 CC SAE CC 17T 12 24 23 231 16 32 27 271 16 32 Phone 608 365 2563 3 L S Standard Assy N Non Standard V Vertical Inverted X Special L Dipstick on Left Side R Dipstick on Right Side N No Dipstick H Pad Mounted Horizontally V Pad Mounted Vertically Fax 608 365 2182 NOMENCLATURE FOR INDEPENDENT INPUT ASSEMBLIES 1PD06 2PD06 2PD08 2PD10 1PD06 1 321 003 CCH LS 2PD08 1 40D 001 CCH DDH RS L 4PD08 4PD09 4PD11 4PD08 1 1 007 CCV CCH CCH CCH LS 3PD06 3PD08 3PD10 3PD06 1 291 002 CCH CCH CCH NS I EL LR INDEPENDENT INPUT 001 1810 Companion 002 1610 Companion 003
14. 101 K12416 1 25 Me 012409 012408 K12203 1 18 Inc 012105 012102 provided in gear box kit but is required in all normal mounted installations left side only Expansion plug P N 012326 is not provided in gear box kit but is required K12201 14 012104 012104 in all inverted installations For replacement gears with K12202 1 18 Dec 012102 012105 bearings assembled order gear as a kit with a K number K12415 1 25 Dec 012408 012409 i e To order a 012104 gear with 2 012015 bearings K12204 1 32 Dec 012101 012106 order as K12104 K12206 1 40 Dec 012100 012107 K12208 1 48 Dec 012099 012108 K12210 1 57 Dec 012098 012109 K12212 1 67 Dec 012097 012110 Phone 608 365 2563 16 Fax 608 365 2182 2PD06 MODULE PUMP DRIVE SEE NOTE FOR DIPSTICK AND PLUG 4400 101 VENT 012166 FITTING D70 WASHER 10 D1353 CAP SCREW 10 A INPUT GEAR 012042 SEAL 012015 BEARING 6 012236 MAGNETIC DRAIN PLUG 012137 OUTPUT HOUSING 012136 INPUT HOUSING The following chart lists all of the complete assembly part Complete Gear Input Output numbers with the prefix of K All of the pump drive gear Box P N Ratio GearA GearB boxes can be purchased as a complete kit and will come K12226 1 67 Inc 012110 012097 fully assembled with all of the part numbers as shown in K12224 1 57 Inc 012109 012098 the above figure including the gears shown in the below K12222 1 48 Inc 012108 012099 table to create the desired ratio
15. 2 SAE Clutch Size SP214 SP214 SP211 C111 C110 Clutch Face Offset 1 00 1 00 1 562 1 562 2 125 Tapped Flywheel Holes 8 1 2 13 8 1 2 13 8 3 8 16 8 3 8 16 6 3 8 16 A Bearing 4202 129 C2059 4202 101 4202 101 4202 101 B Clutch Plate Assy 4263 109 4263 109 4263 106 4263 105 4263 107 C Drive Ring 4265 627 4265 627 4265 618 4265 619 4265 620 D Shift Yoke 4265 634 4265 634 4265 612 4265 614 4265 614 E Shift Handle 4265 633 4265 633 4265 613 4265 613 4265 613 F Operating Shaft 4265 632 4265 632 4265 616 4265 615 4265 615 G Lock Washer 4265 631 4265 631 4265 621 4265 622 4265 622 H Lock Nut 4265 629 4265 629 4265 624 4265 623 4265 623 J Drive Shaft Key 4273 921 4273 921 4273 409 4273 132 4273 132 K Hydraulic Hose Assy 4265 635 4265 635 4265 635 4265 617 4265 617 ve 3 15 diameter pilot bearing 3 94 diameter pilot bearing Note In addition to parts listed in chart above all kits include 2 woodruff keys P N 4273 507 2 lube fittings P N 4400 128 and 1 zerk fitting P N K44 Phone 608 365 2563 31 Fax 608 365 2182 CLUTCH INSTALLATION INSTRUCTIONS 1 Before assembling the clutch onto the Durst pump drive position the pump drive with the input facing up Note The clutch housing and clutch shaft must be in place and secured see pages 28 29 2 Install the operating shaft into the clutch housing and shift yoke The shift handle can be mounted on either side of the operating sh
16. 8 Dec Oil Capacity 6 25 Qts 5 91 Liters 5 75 Qts 5 44 Liters 5 50 Qts 5 20 Liters Note All oil capacities are approximate Refer to Lubrication and Oil Filling Instructions when adding or changing oil Phone 608 365 2563 Fax 608 365 2182 PART NUMBER CHARTS FOR MODULAR GEAR BOXES amp ADAPTERS Due to the modular design of the new pump drives parts list for all the options and service parts for this the number of parts needed to build any model is pump drive line significantly reduced The following charts contain a 1PD06 MODULE PUMP DRIVE SEE NOTE FOR DIPSTICK OR PLUG 012015 BEARING 4 4400 101 VENT 012166 FITTING J84 DOWEL PIN 2 K38 INVERTED OIL LEVEL PLUG 012042 SEAL A INPUT GEAR B OUTPUT GEAR D70 WASHER 7 D1353 CAP SCREW 7 012173 INPUT HOUSING 012236 MAGNETIC DRAIN PLUG 012174 OUTPUT HOUSING The following chart lists all of the complete assembly part Complete Gear Input Output numbers with the prefix of K All of the pump drive gear Box P N Ratio Gear A Gear B boxes can be purchased as a complete kit and will come K12213 1 67 Inc 012110 012097 fully assembled with all of the part numbers as shown in K12211 1 57 Inc 012109 012098 the above figure including the gears shown in the table to K12209 1 48 Inc 012108 012099 create the desired ratio Note Dipstick P N 012306 is not K12207 1 40 Inc 012107 012100 K12205 1 32 Inc 012106 012
17. L CODE SELLER SHALL HAVE NO LIABILITY TO BUYER FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES SUCH AS LOST PROFITS LOST REVENUE DAMAGE TO OTHER EQUIPMENT OR LIABILITY OR INJURY TO A THIRD PARTY ANY ACTION ARISING HEREUNDER OR RELATED HERETO MUST BE COMMENCED WITHIN ONE 1 YEAR AFTER THE CAUSE OF ACTION OCCURS OR IT SHALL BE BARRED NOTWITHSTANDING ANY STATUTORY PERIOD OF LIMITATIONS TO THE CONTRARY AND i In the event of the resale of any of the goods in whatever form Buyer will include the following language in a conspicuous place and in a conspicuous manner in a written agreement covering such resale THE MANUFACTURER MAKES NO WARRANTIES OR REPRESENTATIONS EXPRESS OR IMPLIED BY OPERATION OF LAW OR OTHERWISE AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE GOODS SOLD HEREUNDER BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE GOODS PURCHASED HEREUNDER WILL SUITABLY MEET THE REQUIREMENTS OR THEIR INTENDED USE IN NO EVENT WILL MANUFACTURER BE LIABLE FOR CONSEQUENTIAL INCIDENTAL OR OTHER DAMAGES Revised 03 05 34 Fax 608 365 2182 DURST A REGAL BELOIT Company P O Box 298 Beloit WI 53512 0298 1 800 356 0775 608 365 2563 Fax 608 365 2182 www durstusa com REGAL BELOIT CORPORATION is a worldwide manufacturer of mechanical and electrical motion control products P N 012530 June 2005 4896D 500 06 05 BP NP
18. MATION TOOLS NEEDED Sockets 3 4 5 8 15 16 1 1 8 2 3 8 Allen Wrench 3 8 1 2 Eye Bolts 5 8 3 4 Gear Pullers 5 625 diameter min Scraper Blade Loctite 587 609 or equivalent Wooden Mallet Expansion Plug Remover Snap Ring Pliers Torque Wrench Large Flat Head Punch Adjustable Open end Wrench Large Screw Driver Seal Driver CSV IT Ve A SAN DEFINITIONS Warning Means that there is a possibility of personal injury to yourself or to others Caution Means that there is a possibility of damaging the gearbox or engine it is attached to Note Provides general information Tip Provides information that can help properly complete a specific procedure SAE Society of Automotive Engineers This group defines standards in the automotive industry to allow for interchangeability between engine and component manufacturers Iso Lube Ports located in Terrell pump pads to provide adequate oil lubrication to the pump splines TIR Total Indicator Reading This is a measurement to determine endplay on a rotating element Phone 608 365 2563 Increaser Ratio When the output gears shafts are turning faster than the input shaft Decreaser Ratio When the output gears shafts are turning slower than the input shaft TABLE 1 Bolt Tightening Torques Torque ft lb Size Gr 5 Gr 8 3 8 16 30 45 7 16 14 50 70 1 2 13 75 105 5 8 11 150 210 3 4 10 270 375 Plug Tightening Torques Size T
19. P N Adapter Bolt Holes Adapter K12061 12 7 16 14 012034 K12062 12 3 8 16 012035 K12063 12 3 8 16 012036 K12064 12 3 8 16 012037 Complete Clutch SAE Clutch Engine Mounting Clutch Housing Kit P N Housing Bolt Holes Housing K12267 1 For SP214 Clutch 12 7 16 14 012158 K12268 1 For SP211 Clutch 12 7 16 14 012159 K12270 2 For SP211 Clutch 12 3 8 16 012161 K12271 2 For C111 Clutch 12 3 8 16 012162 K12272 2 For C110 Clutch 12 3 8 16 012163 K12611 3 For SP211 Clutch 12 3 8 16 012610 K12273 3 For C111 Clutch 12 3 8 16 012164 K12274 3 For C110 Clutch 12 3 8 16 012165 CLUTCH HOUSING amp ENGINE ADAPTER INSTALLATION INSTRUCTIONS 1 Place clutch housing or engine adapter onto pump 2 Install lock washers on to adapter mounting cap drive gear box Be sure that clutch housing or engine screws Evenly tighten bolts according to Table 1 see adapter is positioned correctly as this will locate the page 33 weep hole at the bottom and allow moisture to drain Phone 608 365 2563 29 Fax 608 365 2182 DRIVE PLATE OPTIONS The following chart lists all available drive plate options for the Durst pump drives Drive plates are to be purchased as complete kits only Drive Plate SAE Drive Assembly Plate Size X12145 14 X12146 11 5 X12147 10 X12148 8 Drive Plate Tapped Engine Offset Flywheel Holes 1 00 8 1 2 13 1 562 8 3 8 16 2 125 8 3 8 16 2 438 6 3 8 16 NOTE ORIENTATION OF DRIVE PLATE HUB JO D
20. RIVE PLATE INSTALLATION INSTRUCTIONS 1 Remove the drive plate from the Durst pump drive gear box 2 Install the drive plate onto the engine flywheel drive plate hub is to face AWAY from the engine Bolt the drive plate to the engine flywheel tighten bolts according to Table 1 see page 33 3 Check drive plate run out Total TIR should not exceed 0 008 4 Apply Silver Streak 200S to the external splines and slide the input shaft of the pump drive into the drive plate hub until the engine adapter seats against the engine flywheel housing Phone 608 365 2563 Do not use the engine adapter mounting bolts to seat the pump drive engine adapter housing to the engine flywheel housing This may reduce engine crankshaft endplay and will result in premature damage or failure of crankshaft bearings Always check engine crankshaft endplay after installing the flex plate to engine flywheel Refer to engine manufacturer s endplay specifications 30 Fax 608 365 2182 CLUTCH OPTIONS C DRIVE RING K HYDRAULIC HOSE ASSEMBLY E SHIFTER HANDLE H LOCKNUT J DRIVE SHAFT KEY A BEARING G LOCK WASHER The following chart lists all available clutch options for as complete kits or as individual components the Durst pump drives Clutch kits can be either purchased Component Complete Clutch Housing Kit Part Numbers Description K12288 K12289 K12290 K12291 K1229
21. aft Tighten bolt according to Table 1 see page 33 Tip Applying a light coat of oil will allow the shaft to slide into place easier 3 Slide the shift yoke out of place and set the 4273 507 woodruffs keys into the slot on the operating shaft 4 Move the shift yoke into place over the woodruff keys Shift yoke MUST be centered on the operating shaft Tighten bolts according to Table 1 page 33 5 Position the clutch over the clutch housing and install the grease hose to the clutch assembly grease port 6 Carefully lower the clutch onto the clutch shaft and into the clutch housing Using the shift handle align the shift yoke with the mating tabs on the clutch assembly Phone 608 365 2563 7 With the clutch installed press in the drive shaft key 8 Place the lock washer onto the clutch shaft so that the alignment tab is setting in the clutch keyway 9 Thread the lock nut onto the clutch shaft and tighten to 30 ft Ibs To tighten nut turn an additional A For SP214 and SP114 clutches 150 180 Degrees B For SP211 clutch 120 150 Degrees C For C111 and C110 clutches 60 90 Degrees 10 Fold over the two edges of the lock washer to the flats of the lock nut 11 Press on support bearing to the end of the clutch shaft Do not use excessive force when pressing on the support bearing as this could damage the internal gearbox bearings and cause premature failure 32 Fax 608 365 2182 GENERAL INFOR
22. ar box to install the Loctite 609 to the dipstick tube and insert the dipstick tube input seal Apply a small coat of oil to the gear surface until the expanded neck bottoms out on the gear box to allow the seal to properly seat Apply a thin coat of housing In all cases except 1PD06 make certain that the Loctite 609 to the seal O D and press into place 060 second hole is plugged with a 012326 expansion plug below flush with the gear Pressing the seal too far Note that the 1PD06 has only one dipstick location on the will create a leak or possibly block oil to the bearings left side see Figure H Figure H Phone 608 365 2563 11 Fax 608 365 2182 LUBRICATION AND OIL FILLING INSTRUCTIONS Oil flow and circulation in a gear box is one of the most important features to give all internal parts the maximum life The Durst pump drive design incorporates several key features from previous designs ISO LUBE is no longer necessary due to strategically placed oil ports and ribs When filled to the proper level oil will be circulated within the box to each set of bearings and across all the pump splines for smooth operation Because the pump spline adapters and the input shaft are exposed to the oil within the pump drive do not apply grease or any type of corrosion prevention materials to the splines as these will contaminate the gear box oil All Durst pump drives are
23. cknowledges that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their intended use In no event will the manufacturer be liable for consequential incidental or other damages Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section 2 719 of the Uniform Commercial Code the manufacturer shall have no liability to Buyer for consequential damages Resellers Buyers agree to also include this entire document including the warnings and cautions above in a conspicuous place and in a conspicuous manner in writing to instruct users on the safe usage of the product This information should be read together with all other printed information supplied by Durst Phone 608 365 2563 1 Fax 608 365 2182 MODEL IDENTIFICATION A Durst name plate is mounted on every pump drive that is assembled at the factory This nameplate provides the part number the ratio and basic description unit serial number date unit was assembled and recommended oil type Do not paint over remove or tamper with the name plate as this is the only type of identification for warranty repairs or replacement parts If the Durst name plate has been destroyed the following charts can be used to determine the model description NOMENCLATURE FOR CLUTCH ASSEMBLIES 1PD06 2PD06 2PD08 2PD10 3PD06 3PD08 3PD10 1PD06 1 321 343 CCH
24. d in all inverted installations For replacement gears with bearings assembled order gear as a kit with a K number i e To order a 012010 gear with 2 012016 bearings order as K12010 Phone 608 365 2563 REA Complete Gear Box P N K12130 K12129 K12127 K12125 K12123 K12124 K12126 K12128 4400 101 VENT 012166 FITTING 012016 BEARING 6 012042 SEAL A INPUT GEAR B OUTPUT GEAR 3 Ratio 1 53 Inc 1 40 Inc 1 34 Inc 1 23 Inc 1 1 1 23 Dec 1 34 Dec 1 40 Dec J84 DOWEL PIN 2 012114 INPUT HOUSING 012115 OUTPUT HOUSING Input Output Gear A Gear B 012049 012048 012013 012007 012012 012008 012011 012009 012010 012010 012009 012011 012008 012012 012007 012013 20 Fax 608 365 2182 4PD08 MODULE PUMP DRIVE The following chart lists all of the complete assembly part numbers with the prefix of K All of the pump drive gear boxes can be purchased as a complete kit and will come fully assembled with all of the part numbers as shown in the above figure including the gears shown in the following table to create the desired ratio Note Dipstick P N 012309 is not provided in gear box kit but is required in all normal mounted installations It can be installed either left or right side The opposite side is plugged with P N 012326 expansion plug provided with dipstick For replacement gears with bearings assembled ord
25. drive is integral with the input gear through a 29T 12 24 spline The input shaft is contained within the gear box and allows the drive plate or torsional coupling to be free on the input shaft which reduces misalignment stresses from the engine flywheel and the gear box Due to the modular design of the gear box the input shaft can be removed and or replaced without disturbing the internal workings of the gear box DRIVE PLATE The Durst pump drive now uses a four disk drive plate By using 4 thin disks the drive plate becomes slightly wider and increases the rating Thin disks are much more flexible and when multiple disks are put together they absorb more engine vibrations than a single thick disk As mentioned in the Input Shaft section the drive plate is no longer captured on the input shaft instead it is able to automatically adjust if any engine flywheel misalignment occurs These changes result in smoother operation and longer gear box life 5 Fax 608 365 2182 INSTALLATION INSTRUCTIONS INSTALLATION OF DURST PUMP DRIVES There are 3 types of standard inputs that are available with the Durst pump drive models DRIVE PLATE DRIVEN This unit mounts directly to the engine flywheel Use extreme care when mounting the drive plate to the engine flywheel to avoid preloading the crankshaft bearings 1 Install the drive plate onto the engine flywheel drive plate hub is to face AWAY from the engine Bolt the drive plate to the engine
26. earings assembled order gear as a kit with a K number i e To order a 012010 gear with 2 012016 bearings order as K12010 Phone 608 365 2563 4400 101 VENT 012166 FITTING SEE NOTE FOR DIPSTICK AND PLUG D1353 CAP SCREW 12 D70 WASHER 12 Complete Gear Box P N K12092 K12091 K12089 K12087 K12085 K12086 K12088 K12090 A INPUT GEAR 012042 SEAL 012016 BEARING 6 Ratio 1 53 Inc 1 40 Inc 1 34 Inc 1 23 Inc 1 1 1 23 Dec 1 34 Dec 1 40 Dec B OUTPUT GEAR 2 012040 INPUT HOUSING 012041 OUTPUT HOUSING Input Output Gear A Gear B 012049 012048 012013 012007 012012 012008 012011 012009 012010 012010 012009 012011 012008 012012 012007 012013 Fax 608 365 2182 3PD08 MODULE PUMP DRIVE D70 WASHER 16 D1353 CAP SCREW 16 SEE NOTE FOR DIPSTICK AND PLUG K38 INVERTED OIL LEVEL PLUG 012236 MAGNETIC DRAIN PLUG The following chart lists all of the complete assembly part numbers with the prefix of K All of the pump drive gear boxes can be purchased as a complete kit and will come fully assembled with all of the part numbers as shown in the above figure including the gears shown in the following table to create the desired ratio Note Dipstick P N 012294 is not provided in gear box kit but is required in all normal mounted installations lt can be installed either left or right side Two expansion plugs P N 012326 are not provided in gear box kit but are require
27. er gear as a kit with a K number i e To order a 012010 gear with 2 012016 bearings order as K12010 Phone 608 365 2563 SEE NOTE FOR DIPSTICK AND PLUG D1353 CAP SCREW 16 D70 WASHER 16 J84 DOWEL PIN 2 4400 101 VENT 012166 FITTING 012016 BEARING 10 A INPUT GEAR 012042 SEAL 012118 INPUT HOUSING 012119 OUTPUT HOUSING Complete Gear Input Output Box P N Ratio Gear A Gear B K12182 1 53 Inc 012049 012048 K12181 1 40 Inc 012013 012007 K12179 1 34 Inc 012012 012008 K12177 1 23 Inc 012011 012009 K12175 1 1 012010 012010 K12176 1 23 Dec 012009 012011 K12178 1 34 Dec 012008 012012 K12180 1 40 Dec 012007 012013 Fax 608 365 2182 4PD09 MODULE PUMP DRIVE SEE NOTE FOR DIPSTICK AND PLUG D1353 CAP SCREW 16 D70 WASHER 16 J84 DOWEL PIN 2 4400 101 VENT 012166 FITTING 012016 BEARING 10 012042 SEAL A INPUT GEAR B OUTPUT GEAR 4 N 2 ZA VAM SS I y Y k E N d4 LH ENS N AA UF N 012468 INPUT HOUSING 012469 OUTPUT HOUSING The following chart lists all of the complete assembly part numbers with the prefix of K All of the pump drive gear boxes can be purchased as a complete kit and will come fully assembled with all of the part numbers as shown in the above figure including the gears shown in the following table to create the desired ratio Note Dipstick P N 012527 i
28. flywheel see Table 1 page 33 for proper torque specifications when tightening bolts 2 Check drive plate run out Total TIR should not exceed 0 008 3 Apply Silver Streak 200S to external splines and slide the input shaft of the pump drive into the drive plate hub splines until the pump drive engine adapter seats completely into the engine flywheel housing Torque all mounting bolts per Table 1 see page 33 INDEPENDENT SHAFT DRIVEN This unit is designed to be driven with a short coupled drive line connection to the input shaft The input shaft WILL NOT accept any overhung loads i e Belt Sheaves sprockets or severely angled drive lines For over hung load applications contact Durst Engineering CLUTCH DRIVEN This unit mounts directly to the engine flywheel through an over center clutch The clutch is primarily used for disconnecting the pump drive during engine start up Each clutch includes a separate installation parts and service manual 1 The clutch is not preset at the factory and can only be adjusted after being mounted to the engine 2 Check the engine crankshaft endplay prior to installing the clutch driven pump drive Phone 608 365 2563 3 Mount the clutch drive ring to the engine flywheel Refer to the clutch service manual for the proper bolt torques 4 Slide the clutch drive plates into the drive ring and pilot bearing into the engine flywheel until the clutch housing fully seats with the engine f
29. ide Two expansion plugs P N 012326 are not provided in gear box kit but are required in all vertical installations For replacement gears with bearings assembled order gear as a kit with a K number i e To order a 012052 gear with 2 012016 bearings order as K12052 Complete Gear Input Output Dipstick Box P N Ratio Gear A Gear B C K12243 1 38 Inc 012056 012011 012413 K12241 1 29 Inc 012055 012012 012413 K12239 1 21 Inc 012054 012050 012413 K12237 1 1 012052 012052 012310 K12238 1 21 Dec 012050 012054 012413 K12240 1 29 Dec 012012 012055 012413 K12242 1 38 Dec 012011 012056 012413 Phone 608 365 2563 23 Fax 608 365 2182 3PD10 MODULE PUMP DRIVE D70 WASHER 16 D1353 CAP SCREW 16 SEE NOTE FOR DIPSTICK AND PLUG K38 INVERTED OIL LEVEL PLUG The following chart lists all of the complete assembly part numbers with the prefix of K All of the pump drive gear boxes can be purchased as a complete kit and will come fully assembled with all of the part numbers as shown in the above figure including the gears shown in the following table to create the desired ratio Note Dipstick P N 012311 is not provided in gear box kit but is required in all normal mounted installations It can be installed either left or right side Two expansion plugs P N 012326 are not provided in gear box kit but are required in all inverted installations For replacement gears with bearings assembled order gear as a kit with a K n
30. lywheel housing Torque mounting bolts according to Table 1 see page 33 Do not use the engine adapter mounting bolts to seat the pump drive engine adapter or pump drive clutch housing onto the engine flywheel housing This may reduce engine crankshaft endplay and may result in premature damage or failure of crankshaft bearings Always check engine crankshaft endplay after installing the drive plate or clutch to engine flywheel Refer to engine manufacturer s endplay specifications 6 Fax 608 365 2182 MOUNTING PROCEDURES FOR DURST PUMP DRIVES The pump drive is to be supported on a rigid foundation using the mounting holes provided in the pump drive housing Inadequate mounting foundation may result in misalignment or excessive stress on the pump drive housing This can cause undue noise overheating and possible failure Durst pump drive gear boxes can be mounted in several positions to be more adaptive to the customer s application Note To prevent loosening and misalignment bolts must be tightened to the recommended torques specs shown in Table 1 see page 33 2PD06 2PD08 and 2PD10 pump drives can be mounted horizontally or vertically x Refer to arrows that are cast into the housings for mounting direction 1PD06 3PD06 3PD08 and 3PD10 pump drives can be mounted normal or inverted 4PD08 4PD09 and 4PD11 pump drives can ONLY be mounted in the normal orientation Failure to mount boxes in the specified
31. obile SHC 630 Synthetic or equivalent 10 F to 100 F Above 100 F 12 Fax 608 365 2182 6 INCH GEAR CENTERS 1PD06 Normal Mounting 1PD06 Inverted Mounting Ratio Oil Capacity Ratio Oil Capacity 1 67 Inc 2 88 Qts 2 75 Liters 1 67 Inc 2 18 Qts 2 06 Liters 1 57 Inc 1 57 Inc 1 48 Inc 3 00 Qts 2 84 Liters 1 48 Inc 2 31 Qts 2 18 Liters 1 40 Inc 1 40 Inc 1 32 Inc 1 32 Inc 1 25 Inc 1 25 Inc 1 18 Inc 1 18 Inc 1 1 2 75 Qts 2 60 Liters 1 1 2 31 Qts 2 18 Liters 1 18 Dec 1 18 Dec 1 25 Dec 1 25 Dec 1 32 Dec 1 32 Dec 1 40 Dec 1 40 Dec 1 48 Dec 1 48 Dec 1 57 Dec 1 57 Dec 1 67 Dec 1 67 Dec 2 43 Qts 2 30 Liters 2PD06 Normal Mounting 2PD06 Vertical Mounting Ratio Oil Capacity Ratio Oil Capacity 1 67 Inc 3 25 Qts 3 07 Liters 1 67 Inc 3 10 Qts 2 93 Liters 1 57 Inc 1 57 Inc 1 48 Inc 2 88 Qts 2 73 Liters 1 48 Inc 3 60 Qts 3 41 Liters 1 40 Inc 3 13 Qts 2 96 Liters 1 40 Inc 3 60 Qts 3 41 Liters 1 32 Inc 3 50 Qts 3 31 Liters 1 32 Inc 2 20 Qts 2 08 Liters 1 25 Inc 1 25 Inc 1 18 Inc 3 50 Qts 3 31 Liters 1 18 Inc 2 30 Qts 2 18 Liters 1 1 3 62 Qts 3 43 Liters 1 1 3 0 Qts 2 84 Liters 1 18 Dec 1 18 Dec 2 75 Qts 2 60 Liters 1 25 Dec 1 25 Dec 1 32 Dec 2 75 Qts 2 60 Liters 1 32 Dec 2 60 Qts 2 46 Liters 1 40 Dec 3 13 Qts 2 96 Liters 1 40 Dec 1 48 Dec 3 25 Qts 3 07 Liters 1 48 Dec 2 50 Qts 2 36 Lite
32. orque ft lb Fill Drain amp Vent Plugs 33 Fax 608 365 2182 DURST PUMP DRIVE WARRANTY WARRANTIES amp LIMITATIONS OF LIABILITY a Seller warrants to Buyer that the goods will conform to the following warranty The goods will be commercially free from defects in materials and workmanship under normal use for a period of 1 year from the date of shipment of the goods by Seller and will conform at the date of shipment to applicable specifications drawings and blueprints except for departures therefrom with written approval of Buyer provided that work performed by Seller upon blanks and other materials furnished by Buyer is excluded from this warranty Seller shall have no liability to Buyer for cost of blanks furnished by Buyer which are damaged or spoiled during heat treat or machining operations b In the case of drives gears and reducers manufactured by Seller Seller warrants only that such products when shipped shall be capable of delivering the service rating as indicated in Seller s written documents including quotations and catalogs as noted on such products providing such equipment is properly installed and maintained correctly lubricated operating under normal conditions with competent supervision and within the load limits for which it was sold and provided further that the equipment is free from critical speed tortional or other type vibration no matter how induced c If any model or sample was provided
33. r goods which have been altered or repaired by anyone other than Seller or its authorized representative Phone 608 365 2563 f THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE AND OR ANY OTHER TYPE WHETHER EXPRESS OR IMPLIED g Products not manufactured and work not performed by Seller are warranted only to the extent and in the manner that the same are warranted to Seller by Seller s vendors and then only to the extent that Seller is reasonably able to enforce such warranty In enforcing such warranty it is understood Seller shall have no obligation to initiate litigation unless Buyer undertakes to pay all costs and expenses there fore including but not limited to Attorney s fees and indemnifies Seller against any liability to Seller s vendors arising out of such litigation h THE FOREGOING IS SELLER S ONLY OBLIGATION AND BUYER S EXCLUSIVE REMEDY FOR BREACH OF WARRANTY BUYER S FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF INCLUDING BUT NOT LIMITED TO CLAIMS BASED ON LATENT DEFECTS IN NO EVENT SHALL BUYER BE ENTITLED TO INCIDENTAL CONSEQUENTIAL CONTINGENT OR SPECIAL DAMAGES NOR SHALL SELLER S LIABILITY EXCEED THE PURCHASE PRICE OF THE GOODS EVEN IF THE REPAIR OR REPLACEMENT REMEDY SHALL BE DEEMED TO HAVE FAILED OF ITS ESSENTIAL PURPOSE UNDER SECTION 2 719 OF THE UNIFORM COMMERCIA
34. remove all frame mounting bolts NOTE Hydraulic pumps may remain connected however it is recommended for ease of disassembly and cleaning parts that the pumps be removed 4 If replacing the pump pads remove the cap screws or nuts Use a large screwdriver to evenly pry the pump pads loose of the gear box Be careful to lift the pump pads evenly to avoid damaging the pilot To avoid oil leaks all o rings are to be replaced any time the pump pad is removed 5 To access the input shaft retaining ring remove the expansion plug Remove the retaining ring from the input drive shaft and slide the shaft out of the engine adapter side see Figure A NOTE The expansion plug must be replaced any time it is removed Tip Use a rubber or wooden mallet to unseat the shaft o ring from the input gear Phone 608 365 2563 6 Once the input drive shaft is removed place the pump drive on a flat surface with the pump pads facing up Remove the two 2 dowel pins and all the cap screws before attempting to separate the housing halves Use the cap screws in the threaded separating holes to split the housing halves Slightly tap the output housing with a wooden mallet to release the bearings and gears from the bearing bores see Figure B EXPANSION PLUG RETAINING RING Figure B Fax 608 365 2182 7 Evenly lift the output housing half being careful not to lift any of the gears Inspect the gears and bearing
35. rs 1 57 Dec 1 57 Dec 1 67 Dec 2 38 Qts 2 25 Liters 1 67 Dec 2 80 Qts 2 65 Liters 3PD06 Normal Mounting 3PD06 Inverted Mounting Ratio Oil Capacity Ratio Oil Capacity 1 52 Inc 1 52 Inc 3 63 Qts 3 43 Liters 1 36 Inc 1 36 Inc 1 29 Inc 1 29 Inc 1 17 Inc 1 17 Inc 1 1 3 75 Qts 3 54 Liters 1 1 3 31 Qts 3 13 Liters 1 17 Dec 1 17 Dec 1 29 Dec 1 29 Dec 1 36 Dec 1 36 Dec 3 25 Qts 3 08 Liters Note All oil capacities are approximate Refer to Lubrication and Oil Filling Instructions when adding or changing oil Phone 608 365 2563 13 Fax 608 365 2182 8 INCH GEAR CENTERS 2PD08 Normal Mounting Ratio Oil Capacity 1 40 Inc 4 00 Qts 3 79 Liters 1 34 Inc 1 23 Inc 1 1 4 00 Qts 3 79 Liters 1 23 Dec 1 34 Dec 1 40 Dec 4 00 Qts 3 79 Liters 3PD08 Normal Mounting Ratio Oil Capacity 1 40 Inc 5 50 Qts 5 20 Liters 1 34 Inc 1 23 Inc 1 1 5 25 Ots 4 96 Liters 1 23 Dec 1 34 Dec 1 40 Dec 5 00 Qts 4 73 Liters 4PD08 Normal Mounting Ratio Oil Capacity 1 40 Inc 4 25 Qts 4 00 Liters 1 34 Inc 1 23 Inc 1 1 4 38 Qts 4 14 Liters 1 23 Dec 1 34 Dec 1 40 Dec 4 00 Qts 3 78 Liters 9 INCH GEAR CENTERS 4PD09 Normal Mounting Ratio Oil Capacity 1 40 Inc 6 75 Qts 6 39 Liters 1 30 Inc 1 20 Inc 1 1 6 50 Qts 6 15 Liters 1 20 Dec 1 30 Dec 1 40 Dec 6 0 Qts 5 68 Liters 2PD08 Vertical Mounting Ratio 1
36. s for any defects wear or contamination before removal To remove the gears and bearings swiftly and evenly lift from the housing This can be done by hand as the bearings are a slip fit see Figure C 8 With all of the gears removed drive the input seal out towards the engine adapter It is required to change the input seal any time the input gear has been removed from the housing 9 To remove the bearings from the gears use a gear puller or Arbor press see Figure D When rotating gears keep hands and fingers clear from the gear mesh NOTE Bearings MUST be replaced any time they have been removed from the gear Si I C Figure C Phone 608 365 2563 Figure D Fax 608 365 2182 REASSEMBLY INSTRUCTIONS Before reassembling the pump drive gear box make sure that both housings have been cleaned and inspected Because of the modular design of the Durst pump drives the adapter groups can be either installed after the gear box has been assembled or left on during assembly 1 Install the bearing onto the gear with the shield FACING the gear and the open ball bearing facing out see Figure E A TMI BEARING SHIELD ON THIS SIDE come E For proper oil flow it is mandatory that the bearing shield is facing toward the gear 2 Use a flat razor blade to scrape residual sealant from the sealing surfaces of both housing halves
37. s not provided in gear box kit but is required in all normal mounted installations It can be installed either left or right side The opposite side is plugged with P N 012326 expansion plug provided with dipstick For replacement gears with bearings assembled order gear as a kit with a K number i e To order a 012479 gear with 2 012016 bearings order as K12479 Phone 608 365 2563 Complete Gear Input Output Box P N Ratio Gear A Gear B K12487 1 40 Inc 012052 012476 K12485 1 30 Inc 012480 012477 K12483 1 20 Inc 012051 012478 K12481 1 1 012479 012479 K12482 1 20 Dec 012478 012051 K12484 1 30 Dec 012477 012480 K12486 1 40 Dec 012476 012052 22 Fax 608 365 2182 2PD10 MODULE PUMP DRIVE 012059 PLUG 012236 MAGNETIC DRAIN PLUG The following chart lists all of the complete assembly part numbers with the prefix of K All of the pump drive gear boxes can be purchased as a complete kit and will come fully assembled with all of the part numbers as shown in the above figure including the gears shown in the following table to create the desired ratio Note Dipstick see chart for part number is not provided in gear box kit 4400 101 VENT 012166 FITTING SEE NOTE FOR DIPSTICK AND PLUG D1353 CAP SCREW 16 D70 WASHER 16 012042 SEAL A INPUT GEAR 012193 INPUT HOUSING 012194 OUTPUT HOUSING but is required in all normal mounted installations It can be installed either left or right s
38. shipped without oil Verify that the drain plug is tightened to 50ft Ibs 1 Fill pump drive gear box to MAX oil level on dipstick or to the oil level plug DO NOT over fill as this will result in overheating and possible failure of the pump drive 2 It is recommended to change oil after the first 500 hours or 3 months of service which ever occurs first Thereafter and under normal operating conditions Durst recommends that the oil be changed every 1000 hours or 6 months of service 3 Stop engine before attempting to check or add oil 4 Clean around dipstick and oil fill hole before checking or adding oil 5 Drain oil while the unit is still warm Hot oil can cause severe burns Use extreme care when removing lubrication plugs and vents 6 Inspect and clean magnetic drain plug for contamination or metal particles before replacing Phone 608 365 2563 OIL CAPACITY The following charts indicate the quantity of oil that a NEW box requires When changing the oil some residual is left in the box this will require less oil to fill the box than what is shown below Only fill to the MAX oil level on the dipstick or to the oil level plug otherwise overheating may occur Maximum Operating oil temp for all standard oils 210 F 99 C Maximum Operating oil temp for all synthetic oils 250 F 121 C RECOMMENDED OIL LUBRICANT GRADE Below 10 F Mobile SHC 630 Synthetic or equivalent 80w 90 or EP90 APL GL 5 M
39. structions The following and information is supplied to the Buyer for their protection and to provide the Buyer with years of trouble free and safe operation of your REGAL BELOIT CORPORATION product Read ALL instructions prior to operating pump drive Injury to personnel or pump drive failure may be caused by improper installation maintenance or operation WARNING e Written authorization from REGAL BELOIT CORPORATION or its divisions subsidiaries is required to operate or use pump drives in man lift or people moving devices Check to make certain application does not exceed the allowable load capacities published in the current catalog Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which Buyer shall apply the product The application by Buyer shall not be subject to any implied warranty of fitness for particular purpose For safety Buyer or user should provide protective guards over all shaft extensions and any moving apparatus mounted thereon The user is responsible for checking all applicable safety codes in their area and providing suitable guards Failure to do so may result in bodily injury and or damage to equipment Hot oil can cause severe burns Use extreme care when removing lubrication plugs and vents Make certain that the power supply is disconnected before attempting to service or remove any components Lockout the power supply and tag it to prevent unexpected applica
40. t pump spline adapter into gear Some spline adapters have a necked down spline extension For proper spline engagement this extension is to be facing the pump pad see Figure K Phone 608 365 2563 RETAINING RINGS PUMP PAD SPLINE ADAPTER Figure K Due to an internal oil lubrication system do NOT apply any grease or spline lubricant as this will contaminate the oil 3 Install the second retaining ring into the outermost snap ring groove to contain the pump spline adapter see Figure K 26 Fax 608 365 2182 PUMP PAD ADAPTER The following chart lists all available pump pad adapters be purchased as either complete kits or individual for the Durst pump drives The pump pad adapters can components NOTES Complete Pump Pad SAE Pump Pump Pad Cap Screw 1 Both SAE D kits are supplied with nut Adapter Kit P N Pad Size A B P N 4054 302 qty 4 Kit K12449 K12066 A 012023 012060 012079 uses a 1 2 longer stud than kit K12069 The longer stud is to be used K12067 B 012024 012060 012080 onal ayarauig numps awii Tange K12068 G 012025 012060 012081 thicknesses greater than 1 2 inch or 1K12069 D 012026 Stud 012065 012082 a esired 1K12449 D 012026 Stud 012374 012082 2 The D2 option allows for mounting 2K12135 D2 012096 012133 012082 SAE D 2 Bolt pumps in either the horizontal or vertical position This can K12070 E 012027 012133 012083 also be used to mount a standard SAE 3K12356 E45 012355 012133
41. tion of power TORSIONAL VIBRATIONS emanating from many modern diesel engines can cause severe damage to power train components resulting in premature failure To insure the integrity of the power transmission system a torsional vibration analysis should be performed and suitable vibration dampening components utilized when indicated by the analysis Durst is not responsible for damage or failure resulting from diesel engine generated torsional vibrations CAUTION e Lifting supports including eyebolts are to be used for vertically lifting the gearbox only and no other associated attachments or motors If the pump drive cannot be located in a clear and dry area with access to adequate cooling air supply precautions must be taken to avoid the ingestion of contaminates such as water and the reduction in cooling ability due to exterior contaminates Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation Refer to Table 1 for proper torque specifications when tightening bolts In the event of the resale of any of the goods in whatever form Resellers Buyers will include the following language in a conspicuous place and in a conspicuous manner in a written agreement covering such sale The manufacturer makes no warranties or representations express or implied by operation of law or otherwise as to the merchantability or fitness for a particular purpose of the goods sold hereunder Buyer a
42. to be split to service gears and bearings without having to remove the adapters SPLINES The Durst pump drives have a 29T 12 24 internal spline on the gears This allows for a spline adapter to be used on any SAE pump shaft Because the pump shaft is no longer integral with the gear if the pump is changed or replaced a new gear is not required A 29T 12 24 spline significantly reduces wear on both the gears and spline adapters OIL CIRCULATION Extensive testing was done on each Durst pump drive gear box to optimize the quantity of oil in each box at each ratio The new Durst pump drives no longer have the need for Iso Lube ports Instead the Durst pump drives have special oil port locations and oil directing ribs that causes the oil to flow into the pump pad area lubricating the spline adapters and bearings without the need for external pumps Oil volume is critical to make this feature work and the oil level should be checked frequently PUMP PADS The Durst pump pads have been simplified and no longer contain the bearing cup Pump pads can now be removed without disrupting the internal workings and alignment of the bearings and gears inside the gear box As mentioned above the Durst pump pads no longer feature the Iso Lube ports Oil flows into the pump pad area and then patented cast in recesses causes the oil to flow across the spline for wet spline operation Phone 608 365 2563 INPUT SHAFT The input shaft of the Durst pump
43. to the Buyer it was used merely to illustrate the general type and quality of goods and not to warrant that goods shipped would be of that type or quality d UNLESS AUTHORIZED IN WRITING BY A CORPORATE OFFICER OR VICE PRESIDENT NO AGENT EMPLOYEE OR REPRESENTATIVE OF SELLER HAS ANY AUTHORITY TO BIND SELLER TO ANY AFFIRMATION REPRESENTATION OR WARRANTY CONCERNING THE GOODS SOLD UNDER THE SALES CONTRACT AND ANY SUCH AFFIRMATION REPRESENTATION OR WARRANTY HAS NOT FORMED A PART OF THE BASIS OF THE BARGAIN AND SHALL BE UNENFORCEABLE e Seller s sole obligation under the foregoing warranties is limited to either at Seller s option replacing or repairing defective goods or defective parts thereof This warranty does not cover the cost of installation of the new or repaired goods or parts Replacement goods or parts are warranted for the remainder of the warranty period applicable to the goods originally supplied by Seller All claims for allegedly defective goods must be made within 10 days after Buyer learns of such alleged defects All claims not made in writing and received by Seller within such 10 day period shall be deemed waived Buyer shall return a sample of the alleged defective part for Seller s inspection and no other goods shall be returned to Seller within Seller s written consent This warranty shall not extend to goods subjected to misuse abuse neglect accident or improper installation or maintenance incorrect lubrication o
44. umber i e To order a 012052 gear with 2 012016 bearings order as K12052 Phone 608 365 2563 Complete Gear Box P N K12250 K12248 K12246 K12244 K12245 K12247 K12249 012016 BEARING 8 012042 SEAL A INPUT GEAR Ratio 1 38 Inc 1 29 Inc 1 21 Inc B OUTPUT GEAR 3 J84 DOWEL PIN 2 012198 INPUT HOUSING 012199 OUTPUT HOUSING Input Output Gear A Gear B 012056 012011 012055 012012 012054 012050 012052 012052 012050 012054 012012 012055 012011 012056 24 Fax 608 365 2182 4PD11 MODULE PUMP DRIVE The following chart lists all of the complete assembly part numbers with the prefix of K All of the pump drive gear boxes can be purchased as a complete kit and will come fully assembled with all of the part numbers as shown in the above figure including the gears shown in the following table to create the desired ratio Note Dipstick P N 012325 is not provided in gear box kit but is required in all normal mounted installations It can be installed either left or right side The opposite side is plugged with P N 012326 expansion plug provided with dipstick For replacement gears with bearings assembled order gear as a kit with a K number i e To order a 012053 gear with 2 012016 bearings order as K12053 Phone 608 365 2563 D1353 CAP SCREW 18 D70 WASHER 18 J84 DOWEL PIN 2 4400 101 VENT SEE NOTE FOR DIPSTICK AND PLUG

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