Valid for pump P/No: 35 84 70

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

Printed in Sweden 95 11 Dynapac Heavy Equipment AB

We reserve the right to change specifications without notice. Box 504 • S-371 23 KARLSKRONA • SWEDEN
Telephone +46 455-627 00
Telefax +46 455-627 30
Telex 43041 dynkar s
 P/N 35 84 70

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

 P/N 35 84 70 Contents
Notes

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

Notes

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W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 3

 Safety Regulations P/N 35 84 70

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.

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

 P/N 35 84 70 General - Safety Regulations
contd.

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!

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 5
 General P/N 35 84 70
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

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

 P/N 35 84 70 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.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 7

 Sealing of the P/N 35 84 70
drive shaft

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

 P/N 35 84 70 Sealing of the
drive shaft

1. Protecting the drive shaft.

2. Loosen retating ring and remove it.

Press-off the front cover.

3. Inspect:
1.Groove
2.Bore
3.Shaft
4.O-ring

4. Press in new shaft seal into correct

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

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 9

 Sealing of the high P/N 35 84 70
pressure valve HD

Remove valve completely (1).

Control:
O-ring, housing.
Replacement of the tightening nut,
record measure.

Attention!
Check valve setting after installation.

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

 P/N 35 84 70 Sealing of the charge
pressure valve

Remove valve completely.

Attention!
Check valve setting after
installation!

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 11

 Sealing of the P/N 35 84 70
control device

Attention!
Check correct hydraulic zero position!

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

 P/N 35 84 70 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
3

2
1

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 13

 Control device HW P/N 35 84 70

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

 P/N 35 84 70 Dismantling of
the pump

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 15

 Dismantling of P/N 35 84 70
the pump
1. Remove pipe and control module.

2. Remove brake valve.

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

 P/N 35 84 70 Dismantling of
the pump

Pos.1

Brakevalve
Brake valve
Pos.2

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 17

 Dismantling of P/N 35 84 70
the pump
3. Pos. 1 Orifice
Pos. 2 Ball with spring

Pos.1

Pos.2

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

 P/N 35 84 70 Dismantling of
the pump

Chargepump assembly
Chargepump assembly

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 19

 Dismantling of P/N 35 84 70
the pump
4. Mark the pump and remove gear pump.

5. Remove gear set.

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

 P/N 35 84 70 Dismantling of
the pump

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 21

 Dismantling of P/N 35 84 70
the pump

6. Check:
Throttle valve

7. Unscrew locking screws.

8. Remove control module.

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

 P/N 35 84 70 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. Pull out control piston.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 23

 Dismantling of P/N 35 84 70
the pump

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

 P/N 35 84 70 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 - note positions of

locating pin and hole drilling.

14. Remove joint pins.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 25

 Dismantling of P/N 35 84 70
the pump

Remove rotary group.

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

 P/N 35 84 70 Dismantling of
the pump
15. Remove cover ring.

16. Remove drive shaft with

slight hammer strokes.

17. Remove cradle with bearing cups.

18.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 27

 Inspection notes P/N 35 84 70

1. Replace all bearings.

2. Check:
1.Splines for damage or fretting
2.Running surfaces
3.Grooves cut by shaft seal

3. Check:
Bearing surfaces (1)

2 4. Check:
Sliding surface (1) free of scoring.
2 Make sure sliding ring/swivel pin (2)
are free of pay.

5. Check:
That return device is free of scoring (1),
no wear in slipper pad area.
(Otherwise: replace both parts together).

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

 P/N 35 84 70 Inspection notes

6. Check:
That there are no scratches or metal
deposits on sliding surface (1), and
there is no (or little) axial play (2).
(Otherwise: pistons 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
embedded foreign particles. No
scratches on the valve plate (2).
(Replace ONLY in sets).

9. Check:
Fit control piston and swash plate.
Pin bearing (1), groove in control
piston (2).

10. Check:
That the control piston guide is not
scored.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 29

 Pump assembly P/N 35 84 70

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 attention for correct seat
of the swivel cradle in the housing.

5. Remove rubber ring.

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

 P/N 35 84 70 Pump assembly

6. Assemble articulating pin.

7. Assemble device for fixation of the

swivel cradle.

8. Assemble drive shaft with bearings

and radial seal rings.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 31

 Pump assembly P/N 35 84 70

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

 P/N 35 84 70 Pump assembly

9. Assemble piston with retaining plate.

Note:
Oil piston and piston pad.

10. Assemble cylinder completely.

11. Remove assembly device.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 33

 Pump assembly P/N 35 84 70

12. Insert O-ring with grease.

Insert fixing pin (1).

13. Control plate, clockwise - located in

direction of rotation. When the casting
of the housing are visible trough the
hole in the valveplate.

14. Place control plate with grease.

Control plate, clockwise - located in
direction of rotation. Web of the port
plate visible. As in above.
Attention!
Noise notches are ground in required
direction of rotation.

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

 P/N 35 84 70 Pump assembly

15. Place in correct position.

16. Insert positioning piston into the

housing.
Note:
Oil positioning piston before assembly.

17. Insert O-rings with grease.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 35

 Pump assembly P/N 35 84 70

18. Assemble control module.

Assembly assistance:
Turn at zero position.

19. Fit charge pump.

20. Assemble pressure charge valve.

21. Assemble control module with pipe.

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

 P/N 35 84 70 Tightening torques

Tightening torques for shaft bolts

(Metric ISO Standard Thread)
Strength Classes
The values for tightening torques
Thread 8.8 10.9 12.9
shown in the table are valid only for
size Tightening Torque (Nm)
shaft bolts with metric ISO- standard
M3 1,1 1,6 1,9
threads and head support surface
M4 2,9 4,1 4,9
dimensions in accordance with DIN
912, DIN 931 and DIN 933. These M5 6 8,5 10
values are also valid only for light or M6 10 14 17
unoiled, untreated surface as well as M8 25 96 41
for use only with torque-indicating M10 49 69 83
wrenches and force limiting tools. M12 86 120 145
M14 135 190 230
M16 210 295 355
M18 290 405 485
M 20 410 580 690
M 22 550 780 930
M 24 710 1000 1200
M 27 1050 1500 1800
M 30 1450 2000 2400

Tightening torques for locking screws VSTI

(Metric ISO fine thread)
Thread size Designation Tightening torques (Nm)
M8x1 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 1,5 -ED/SA = 50
M 22 x 1,5 VSTI 22 x 1,5 -ED = 60
M 26 x 1,5 VSTI 16 x 1,5 -ED/SA = 70
M 27 x 2 VSTI 27 x 2 -ED = 90
M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 100
M 33 x 2 VSTI 33 x 2 -ED/SA = 120
M 42 x 2 VSTI 42 x 2 -ED/SA = 200
M 48 x 2 VSTI 48 x 2 -ED = 300

Tightening torques for cross-slotted lens head screws

Tightening torques for seal-lock nuts DIN 7985
(Metric ISO-Standard Thread) (Metric ISO- Standard Thread)
Strength classes
Strength classes
The values for tightening torques Thread 8.8 10.9 12.9 The values for tightening torques
Thread 8.8 10.9 12.9
shown in the table are valid only for size Tightening torque (Nm) shown in the table are valid only for
size Tightening torques (Nm)
seal-lock nuts of the strength class 8.8 M6 10 cross-slotted lens head screws DIN
M3 1,1
and with metric ISO-standard thread. 7985 of the strength class 8.8 and with
M8 22
M4 2,9
metric ISO-standard thread.
M 10 40
M5 6
M 12 69
M6 10
M 14 110
M8 25
M 16 170
M10 49

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 37

 Adjustment instructions P/N 35 84 70
Mechanical "zero position"

HW

Attention!
Observe safety regulations!
Connect both control chambers 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.
Note:
Death line of zero position.
Swiveled out to the right -
swiveled out to the left.

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

 P/N 35 84 70 Adjustment instructions
Hydraulic "zero position"

HW

Attention!
Observe safety regulations!

Connect manometer to X1 and X2.

Adjust zero position so that at blocked
drive both manometer indicate the
same pressure value.
Note:
Eccentric adjusting
- Do not turn over ±90°.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 39

 Adjustment instructions P/N 35 84 70
HP-valves (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 value.
("Temperature" only for short time)
Change "setting value" - check.

Note:
Adjusting data according to order.

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

 P/N 35 84 70 Adjustment instructions
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 pH - 18 bar
Peak pressure pH - 40 bar
at max. speed.

Note:
Adjusting data according to order.

W-1012-2EN Hydr Propulsion Pumps CC 102/102C/122/122C 41