Dynapac CC102 Workshop Download Page 3 | Manualshive

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P/N 35 84 70

W-1012-2EN Hydr Propulsion Pumps

CC 102/102C/122/122C

3

Contents

Page

Contents, Notes ............................................................................................................. 3
Safety Regulations ...................................................................................................... 4-5
General dismantling ....................................................................................................... 6
General reassembly ....................................................................................................... 7
Sealing of the drive shaft ................................................................................................ 8
Sealing of the high pressure valve ............................................................................... 10
Sealing of the charge pressure valve ........................................................................... 11
Sealing of the control device ........................................................................................ 12
Control device HW ....................................................................................................... 14
Dismantling the pump................................................................................................... 15
Inspection notes ........................................................................................................... 28
Pump assembly ............................................................................................................ 30
Tightening torques ....................................................................................................... 37
Adjustment instructions - Mechanical "zero position" ................................................... 38
Adjustment instructions - Hydraulic "zero position" ...................................................... 39
Adjustment instructions - High pressure valve ............................................................ 40
Adjustment instructions - Low pressure valve (Charge pressure) ................................ 41

Contents

Notes

Notes

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Summary of Contents for CC102

Page 1: ...1012 2EN Valid for pump P No 35 84 70 Printed in Sweden 95 11 We reserve the right to change specifications without notice Dynapac Heavy Equipment AB Box 504 S 371 23 KARLSKRONA SWEDEN Telephone 46 4...

Page 2: ...P N 35 84 70 2 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN...

Page 3: ...re valve 10 Sealing of the charge pressure valve 11 Sealing of the control device 12 Control device HW 14 Dismantling the pump 15 Inspection notes 28 Pump assembly 30 Tightening torques 37 Adjustment...

Page 4: ...serve the guidelines of the machine manufacturer and safety manual A 281 Before starting Study and understand the operating instructions before starting Check the machine for any serious faults Do not...

Page 5: ...s injury Therefore immediately consult a doctor if such injury occurs Serious infec tion may otherwised be caused 2 When searching for leaks use appropriate means because of the danger of acci dents 3...

Page 6: ...ore the following points must be given particular attention Dismantling 1 When dismantling the unit from the machine immediately close openings with plugs to prevent ingress of dirt 2 Make note of the...

Page 7: ...imum cleanliness 3 Assembly is carried out in reverse order to dismantling unless otherwise stated e g Bearings in Front Case to be pre loaded 4 Fundamentally do not reuse old seals 5 Oil components b...

Page 8: ...P N 35 84 70 8 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Sealing of the drive shaft...

Page 9: ...the drive shaft 3 Inspect 1 Groove 2 Bore 3 Shaft 4 O ring 1 Protecting the drive shaft 2 Loosen retating ring and remove it Press off the front cover 4 Press in new shaft seal into correct position w...

Page 10: ...sion Pumps CC 102 102C 122 122C W 1012 2EN Remove valve completely 1 Control O ring housing Replacement of the tightening nut record measure Attention Check valve setting after installation Sealing of...

Page 11: ...P N 35 84 70 W 1012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 11 Remove valve completely Attention Check valve setting after installation Sealing of the charge pressure valve...

Page 12: ...P N 35 84 70 12 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Sealing of the control device Attention Check correct hydraulic zero position...

Page 13: ...84 70 W 1012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 13 Sealing of the control device 1 Remove pipe Remove fixing screws Lever of control device 2 Check 1 Sealing face 2 Gasket 3 Outlet orifice...

Page 14: ...P N 35 84 70 14 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Control device HW...

Page 15: ...P N 35 84 70 W 1012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 15 Dismantling of the pump...

Page 16: ...P N 35 84 70 16 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Dismantling of the pump 1 Remove pipe and control module 2 Remove brake valve...

Page 17: ...P N 35 84 70 W 1012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 17 Dismantling of the pump Pos 1 Pos 2 Brake valve Brakevalve...

Page 18: ...P N 35 84 70 18 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Dismantling of the pump Pos 1 Pos 2 3 Pos 1 Orifice Pos 2 Ball with spring...

Page 19: ...P N 35 84 70 W 1012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 19 Dismantling of the pump Chargepump assembly Chargepump assembly...

Page 20: ...P N 35 84 70 20 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Dismantling of the pump 4 Mark the pump and remove gear pump 5 Remove gear set...

Page 21: ...P N 35 84 70 W 1012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 21 Dismantling of the pump...

Page 22: ...P N 35 84 70 22 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Dismantling of the pump 6 Check Throttle valve 7 Unscrew locking screws 8 Remove control module...

Page 23: ...ydr Propulsion Pumps CC 102 102C 122 122C 23 Dismantling of the pump 9 Mark cover Record measure of the adjustment screw Loosen locknut hold adjustment screw 10 Unscrew locking screws Remove O ring 11...

Page 24: ...P N 35 84 70 24 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Dismantling of the pump...

Page 25: ...Dismantling of the pump 12 Release port plate fixing Lift port plate If necessary use screw driver but only in this position in the corners Opposite sides sealing surfaces 13 Lever off control plate...

Page 26: ...P N 35 84 70 26 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Dismantling of the pump Remove rotary group...

Page 27: ...N 35 84 70 W 1012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 27 Dismantling of the pump 15 Remove cover ring 16 Remove drive shaft with slight hammer strokes 17 Remove cradle with bearing cups 18...

Page 28: ...1 Splines for damage or fretting 2 Running surfaces 3 Grooves cut by shaft seal 3 Check Bearing surfaces 1 2 2 1 4 Check Sliding surface 1 free of scoring Make sure sliding ring swivel pin 2 are free...

Page 29: ...ons must be replaced in sets 7 Check Cylinder drillings 1 teeth 2 Otherwise replace cylinder complete with port plate 8 Check Cylinder gliding surface 1 free of scratches no traces of wear and no embe...

Page 30: ...embly 1 Insert bearing cup set 2 Assemble bearing wire Assistance Use bearing with grease or fix the bearing with rubber ring 3 Rubber ring 4 Insert completely swivel cradle into the housing Pay atten...

Page 31: ...0 W 1012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 31 Pump assembly 8 Assemble drive shaft with bearings and radial seal rings 7 Assemble device for fixation of the swivel cradle 6 Assemble artic...

Page 32: ...P N 35 84 70 32 Hydr Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Pump assembly...

Page 33: ...84 70 W 1012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 33 Pump assembly 11 Remove assembly device 10 Assemble cylinder completely 9 Assemble piston with retaining plate Note Oil piston and pisto...

Page 34: ...tation When the casting of the housing are visible trough the hole in the valveplate 12 Insert O ring with grease Insert fixing pin 1 14 Place control plate with grease Control plate clockwise located...

Page 35: ...012 2EN Hydr Propulsion Pumps CC 102 102C 122 122C 35 Pump assembly 15 Place in correct position 17 Insert O rings with grease 16 Insert positioning piston into the housing Note Oil positioning piston...

Page 36: ...Propulsion Pumps CC 102 102C 122 122C W 1012 2EN Pump assembly 18 Assemble control module Assembly assistance Turn at zero position 19 Fit charge pump 20 Assemble pressure charge valve 21 Assemble con...

Page 37: ...1 VSTI 8 x 1 ED SA 5 M 10 x 1 VSTI 10 x1 ED 10 M 12 x 1 5 VSTI 12 x 1 5 ED 20 M 14 x 1 5 VSTI 14 x 1 5 ED 30 M 16 x 1 5 VSTI 16 x 1 5 ED SA 30 M 18 x 1 5 VSTI 18 x 1 5 ED SA 40 M 20 x 1 5 VSTI 20 x 1...

Page 38: ...ambers with hose NW6 Avoidance of rest signal from hydraulic zero position Connect manometer to MA and MB Adjust zero position so that at blocked drive both manometer indicate the same pressure valve...

Page 39: ...39 Adjustment instructions Hydraulic zero position HW Attention Observe safety regulations 1 Connect manometer to X1 and X2 Adjust zero position so that at blocked drive both manometer indicate the s...

Page 40: ...s High pressure Attention Observe safety regulations Note Readjusting only at operating temperature Connect manometer to MA and MB HP valves Operate valves with small pump flow volume Check setting va...

Page 41: ...uctions Low pressure valve Charge pressure Attention Observe safety regulations Note Readjusting only at operating temperature Connect manometer to G Attention Charge pressure setting Nominal pressure...

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