Dynapac CC102 Instruction manual

Workshop
CC 102/102C/122/122C
Hydr Propulsion Pumps
W-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 [phone]
Telefax [phone]
Telex 43041 dynkar s

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2 Hydr Propulsion Pumps CC 102/102C/122/122C W-1012-2EN

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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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4 Hydr Propulsion Pumps CC 102/102C/122/122C W-1012-2EN
General advice
· Make yourself familiar with the equipment of the machine.
· Only operate the machine if your are completely familiar with the
operating and control elements as well as the functioning of the machine.
· Use your safety equipment like helmet, safety shoes and hearing protection.
· Make yourself familiar with your working field.
· Only operate the machine for its intended purpose.
Please observe 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 operate the machine with defective instruments, warning lights or control
elements.
· All safety devices must be in a secure position.
· Do not carry loose objects or secure them to the machine.
· Keep oily and inflammable material away from the machine.
· Before entering the driver's cab, check if persons or obstacles are in the way of or
underneath the machine.
· Be careful when entering the driver's cab, use the steps.
· Adjust your seat before starting.
Safety Regulations

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W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 5
Start
• When starting, all operating levers must be in ”neutral position”.
• Only start the machine from the driver’s seat.
• Check the indicating instruments after start to ensure that all functions are in
order.
• Do not leave the machine unattended when the engine is running.
• When starting with battery connection cables, connect plus to plus and minus
to minus.
• Disconnect the earth (negative) first. Connect it last.
Warning
Exhaust fumes is dangerous. Ensure sufficient fresh air when starting in
closed rooms!
Hydraulic equipment
1. Hydraulic equipment is under high pressure.
Fluids (fuel, hydraulic oil) which escape under high pressure can penetrate
the skin and cause serious 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. Before working on hydraulic equipment, de pressurize to zero and lower the
working arms of the machine.
4. When working on hydraulic equipment, switch of the engine and secure roller
against rolling away (e. g. parking brake)!
5. When connecting hydraulic cylinders and motor, pay attention to correct connec-
tion of flexible hydraulic hoses.
6. The resulting functions will be vice versa if the ports are interchanged (e. g. for-
ward or reverse), creating danger of accidents!
7. Check flexible hydraulic hoses regularly and replace them in case of damage or
wear!
The new hose or pipe must comply with the technical requirements of the ma-
chine manufacturer!
Orderly disposal or recycling of oil, fuel and filters!
General - Safety Regulations
contd.

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6 Hydr Propulsion Pumps CC 102/102C/122/122C W-1012-2EN
General
Dismantling
General
The following repair instructions are intended to assist in inspections and repairs to
be carried out, the instructions are valid for two pumps. When ordering in going parts
to your pump, please use the catalogue that was delivered with the roller. Also inform
us of the machines S/N and the P/N and S/N for the pump. That will allow us to use
our special knowledge and guarantee that the correct parts are delivered. Prerequisite
is that this work is carried out only by qualified personnel.
These units are manufactured with great care and with adherence to defined
tolerances to the highest manufacturing accuracy, and therefore 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 details on code plate, such as serial number, type number
and running time of unit (for ordering spare parts).
3. Remove external dirt (cleaning spirit or trichlor solution).
4. Have a clean work place ready, lay out tools ready.
5. Use only non-threading cleaning rags.
6. Before dismantling components, mark parts to ensure correct re-assembly.
7. Carry out step by step dismantling.
8. The appearance of the parts removed often gives an indication of the condi-
tion of the system. For example:
Scored sliding surfaces, - contaminated operating fluid
heavy abrasion
Discoloration of components - overheating of operating fluid,
with heavy loading incorrect choice of viscosity
or inadequate specifications
of operating fluid
- insufficient oil

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General
Reassembly
Reassembly
1. Use only genuine spare parts. We recommend the use of pre-assembled,
coordinated and tested component groups. The required component groups
and seal kits should be selected from the spares list and ordered by quoting
the code plate details.
2. Assembly should be carried out observing the maximum 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 before assembly (hydraulic mineral oil).
6. Tighten screws with torque wrench according to specifications. If there is any
suspicion of stripping of threads, use new screws.
7. When carrying out dismantling/reassemble instructions refer to the
appropriate drawings.
Important
On completion of repair, close all openings with plugs. Should difficulties
arise, please contact our nearest service centre.

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8 Hydr Propulsion Pumps CC 102/102C/122/122C W-1012-2EN
Sealing of the
drive shaft

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Sealing of 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 with a suitable bush.
Assemble in reversed order.
Check correct seat of the circlip.

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10 Hydr Propulsion 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 the high
pressure valve HD

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Remove valve completely.
Attention!
Check valve setting after
installation!
Sealing of the charge
pressure valve

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Sealing of the
control device
Attention!
Check correct hydraulic zero position!

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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
12
3

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14 Hydr Propulsion Pumps CC 102/102C/122/122C W-1012-2EN
Control device HW

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Dismantling of
the pump

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Dismantling of
the pump
1. Remove pipe and control module.
2. Remove brake valve.

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Dismantling of
the pump
Pos.1
Pos.2
Brake valve
Brakevalve

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Dismantling of
the pump
Pos.1
Pos.2
3. Pos. 1 Orifice
Pos. 2 Ball with spring

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Dismantling of
the pump
Chargepump assembly
Chargepump assembly

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Dismantling of
the pump
4. Mark the pump and remove gear pump.
5. Remove gear set.