General Repairs Tests Tools Parts. Minors Bearing support Torque module Valving - ALL. Page 2 Version A 31-JUL-2017 Poclain Hydraulics, 2017 B42192K

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2 Page 2 Version A 31-JUL-2017 Poclain Hydraulics, 2017 B42192K

3 Xxxxxxxx Xxxxxx Xx xxxx Xxxxxxx Xxxxxx Xxxxx xxxxxx Xx xxxxxxx Xx xxxxxxxx Xxxxxx Xxxxx xxxxxx xxx Xxxxxxx xxx Xx xxxxxx General Repairs Tests Tools Parts About this document Foreword This document is intended for manufacturers of machines that incorporate Poclain Hydraulics products or for repair centers network that service Poclain Hydraulics products. It gives the necessary operating instructions concerning repair and diagnostic of Poclain Hydraulics products. These operating instructions should be read and studied carefully and thoroughly: To ensure reliable repair and diagnostic work To avoid product or machine damage To prevent any personal injuries Symbols used This document includes important instructions concerning safety. They are indicated in the following way: Safety instructions. This document also includes essential operating instructions for the product and general information. These are indicated in the following way: Essential instruction. General information. Reference to section Value. Reference to the Tooling catalog. Reference to other document. Measurement units All measures are expressed in accordance with International System of Units. Converted values to other system (notably US) are in italic between brackets. These are given for information only. -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 3

4 Staff, workshop equipments and safety Staff requirements Poclain Hydraulics products must only be installed and repaired by qualified technicians. A qualified technician is someone who: Has a minimum mechanical and hydraulic knowledge, Followed required trainings to perform correctly the repair operations, Is able to read and fully understand information given in this document, especially the safety instructions, Is able to evaluate his tasks and risks that could result, Is able to prevent risks of accidents and personal injury by taking necessary safety measures, Is able to prevent risks of environmental pollution, Is able to comply with guidelines, standards, laws and regulations in force in his country. Technicians must wear personal protective equipment (PPE) to avoid physical injury see chapter Safety. It is strictly forbidden for any person under influence of alcohol, drugs or medical treatment to perform the repair operations of products Poclain Hydraulics. Managers of repair workshops must absolutely ensure their technicians comply with the instructions mentioned in this document, the laws and regulation in force in their country. It is their responsibility to enforce these ones, give the required training for technicians and provide adequate protective equipment. Poclain Hydraulics disclaims liability for personal injuries resulting from a failure to respect safety instructions or mishandling. Workshop equipments Premises Repair of Poclain Hydraulics products should be performed in a roofed and well-lit workshop. Ground and walls should be clean to avoid products pollution by external contaminants (dust, metal particles, water...). Required equipment Workstation equipped with a waste oil collector to collect oil at the time of products opening and thus, avoid spilling it on the ground and a compressed air source with air gun to eliminate contaminants from parts before their assembly. Cleaning station composed of wash sink supplied with degreasing fluid and brush to clean parts and subassemblies. An exhaust ventilation system is required to avoid risks of toxic fumes inhalation. Hydraulic press with required capacity to perform disassembly, reassembly and shimming operations of subassemblies: see force values under section Values of this document. The press should be installed in a sufficient space without equipment or parts storage around it to make easier parts handling and press operations. Overhead travelling crane or jib crane near the workstation equipped with a suitable hoist capacity to handle products and sub-assemblies. See weight of products in the technical catalogs. Standard tooling including wrenches, hex keys, pliers, retaining ring pliers, screwdrivers, nylon mallets, torque wrenches, Vernier or digital calipers and depth gauges Poclain Hydraulics recommends that measure equipment is checked and calibrated annually by a nationally accredited laboratory. Page 4 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

5 Staff, workshop equipments and safety Specific tooling to procure or manufacture from information and drawings contained in this document. These tools are intended solely for the repair of Poclain Hydraulics products: they are not suitable for repair of other products. Some tooling is identified with a part number without dimensioned drawing: these must compulsorily be bought to Poclain Hydraulics. Using wood (mallet, blocks or worktable) is strictly prohibited. Grease During the repair process use: Anti-oxidizing grease Auto-top 2000 origin AGIP, fluorescent green color. Oil During the testing process use: standard HV46 oil. Safety It is mandatory to read carefully and understand the safety instructions indicated in this chapter before starting the repair work on products. Poclain Hydraulics products are installed as components on mobile machines or industrial systems. The safety instructions indicated in this chapter relate only Poclain Hydraulics products. Please refer to safety instructions described in the documentation of manufacturers of mobile machines or industrial systems. Personal protective equipment (PPE) Technicians must mandatorily wear personal protective equipment during repair operations of Poclain Hydraulics products. These equipment must be conformed labor law in force in the country. Protective clothes: against cuts and projections of hydraulic fluids, chemicals or metal particles. Safety footwear: to prevent risks of foot crushing, cuts or perforation caused by falling parts. Eye protection: against physical contacts with chemicals (toxic fumes, spray can) and projections of hydraulic fluids, metal particles or dusts. Hearing protection: against the noise from 85 decibels (compressed air tooling, test bench). Protective gloves: against cuts and physical contacts with hydraulic fluids and chemicals. Respiratory protection: against inhalations of toxic fumes, spray can or dusts. -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 5

6 Page 6 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

7 P20 bearing support overview P20 bearing support with integrated parking brake -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 7

8 Disassembly Place bearing support into the special tool to protect the studs. Remove the SR-ring (1770). Ref.:TO Use special tool and press to remove the cut split ring (1770). Use force F max = 161, 3 kn. Ref.:TO Use a special tool to remove two male pins (1020) from bearing support (1005). Ref.:TO Page 8 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

9 Use lifting lugs to remove the bearing support (1005) from the brake body (2005. Lift carefully to slowly release the spring washer! Use a special tool and press to remove the inner part of bearing (1305) from the bearing support (1005). Ref.:TO Use an extractor to remove the outer part of the bearing (1305) from the bearing support (1005). -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 9

10 Remove the spring washer (2040) from the brake body (2005). Use pliers to remove two female pins (1020) from the brake body (2005). Remove and discard O-ring (2326). Remove the pressure washer (2090) from the brake body (2005). Remove the shim/shims ( ,2440,2445) Use magnet to remove the external and internal brake discs (2405 and 2410) from the brake body (2005). Page 10 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

11 Use special pliers to remove the snap ring (1750). Remove the sleeve (2750) from the shaft (1105). Use ENERPAC hydraulic set to push out and separate the shaft (1105) from the brake body (2005). Screw in the lifting lugs and use them to lift the brake body (2005) from the shaft (1105) once they are separated. Be careful! Do not damage the splines when you lift the brake body -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 11

12 Use a special tool to remove the brake piston (2305) from the brake body (2005). Ref.:TO Using a screwdriver or a needle, remove the oil seal (1505) from the brake body (2005). Use an extractor to remove the outer ring of bearing (1205) from the brake body (2005). Use an extractor to remove the inner sleeve (1410) from the brake body (2005). Page 12 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

13 Remove the inner part of bearing (1205) and environmental seal (1405) from the shaft (1105). -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 13

14 Assembly Place the shaft (1105) into the special tool to protect the studs during the work. Apply small amount of grease into the lips of environmental seal (1405) and install it onto the shaft (1105). Ref.:TO Heat the inner part of bearing (1205) for 140 C. Install the inner part of the bearing (1205) onto the shaft (1105). Use appropriate gloves while manipulating with hot bearing. Apply a layer of grease on the bearing. Bearing must be oriented correctly! With wider side facing down. Page 14 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

15 Use a plastic hammer to install inner sleeve (1410) into the brake body (2005). Visually check the fitting, there should be no space between the lip of the sleeve and brake body. Use a special tool and a press to install the outer ring of bearing (1205) into the brake body (2005). Ref.:TO Use lifting lugs to lift the brake body and install the brake body (2005) onto the shaft (1105). Manually push it in place. -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 15

16 Use a special tool to protect the seal from splines while installing it. Apply small amount grease on inner diameter of the oil seal (1505) and install it onto the shaft inside brake body (2005). Pay attention to correct orientation of the oil seal! Flat side must face downward. Ref.:TO Screw in the plugs (2360 and 1960) and bleed screw with bonded seal (1950 and 1955). Necessary tightening torques are - Torque for 2360 M16: 50+/-5N.m G3/8-19: 50+/-5N.m 9/16-18 UNG: 35+/-3N.m Torque for /-3N.m Torque for /-1N.m Lubricate them with oil and install two D-rings (2310 and 2315) into the brake piston (2305). Page 16 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

17 Apply layer of oil on the mating surfaces of brake piston (2305) and in brake body (2005). Use a special tool and a press to insert brake piston (2305) into the brake body (2005). Ref.:TO Install the brake sleeve (2750) onto the shaft (1105). Manually push it down on the shaft. Install the snap ring (1750) onto the shaft to secure the brake sleeve (2750). Insert brake discs (2405 and 2410) into the brake body (2005). Insert discs in correct order! Start with the internal disc and end with external disc. Insert two shims and pressure washer (2090) into the brake body (2005). -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 17

18 Use special tool and a press. Put a special tool on the pressure washer (2090) and apply force F = 65kN. X1 = 25,41 ± 0,1 mm B = 22 ± 0,05 mm A must be measured X = A + B While the force is applied on the brake, take a measure of value A. Final value X must be equivalent to X1 or be in tolerance. If the value is not correct, remove the tool and add necessary amount of shims and redo the measurement process until X1=X is reached. Ref.:TO Install spring washer (2040) into the brake body (2005). Respect the spring washer orientation! Page 18 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

19 Insert two female pins (1020) into the brake body (2005). Install O-ring (2326) into the grove in the brake body (2005). Use press and a special tool to install outer ring of bearing (1305) into the bearing support (1005). Ref.:TO Insert two male pins (1020) into female pins, but don t hammer in them yet. Using a lifting lugs, lift bearing support (1005) and place it onto the brake body (2005). Use pins for correct orientation. -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 19

20 Use a special tool and press to insert inner part of bearing (1305) into the outer ring of the bearing inside bearing support (1005). Use force F max = 161, 3 kn. Use press to create pressure on the shaft to avoid its movement. Recommended force is 20 +/-10 kn. Insert plugs into ports on the opposite side of the motor. Use the oil pump to create pressure 30 bar to release the brake. Recommended is closing valve to possibility rotate with bearing support. Wait 1 minute and check, if the pressure doesn t decreasing. Keep motor pressurized for the next step. Use special tool to measure torque without preload. Turn five times CW and five times CCW and find value C1. Ref.:TO Count C1 + C2 = C, resulting torque. C2 nominal = 50 Nm. Page 20 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

21 Apply the force F max = 161, 3 kn on the bearing (1305) with special tool. Ref.:TO Measure the torque on the shaft. If is value lower then C, increase applied force. Measure height of the cut split ring with applied force corresponding with right torque. While still under the press insert both sides of cut split ring (1760) to secure the shaft. Install SR-ring (1770) onto the shaft (1105) to secure the split ring. -GEN-EN Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 21

22 P20 bearing support Item Description Item Description 1000 Bearing support assembly 2410 Internal brake disc 1005 Bearing support body 2405 External brake discs 1105 Bearing support shaft 2750 Brake sleeve 1205 Front roller bearing 1750 Snap ring 1305 Rear roller bearing 1405 Environmental seal 1410 Inner sleeve 1505 Oil seal 1760 Cut split ring 1960 Plug 1770 SR ring 2430 Shim 2360 Plug 2310 D-Ring 2005 Brake body 2315 D-Ring 1950 Bleed screw 2326 O-Ring 1955 Bonded seal 1020 Pins 2040 Washer spring 1010 Studs 2305 Brake piston 2090 Washer Page 22 Version A 31-JUL-2017 Poclain Hydraulics, GEN-EN

23 History of modifications Version Date Description Visa A 31-JUL Creation D.Jezercak A 31-AUG Check of document V.Rezabek B42192K Poclain Hydraulics, 2017 Version A 31-JUL-2017 Page 23

24 31-JUL-2017 B42192