SVEDALA COMPACTION AND PAVING

DYNAPAC CC 222/232
WORKSHOP MANUAL
CHARGE & STEERING PUMP
W1040EN2

Svedala Compaction Equipment AB

Box 504, SE-371 23 Karlskrona, Sweden
Phone: +46 455 30 60 00, Fax: +46 455 30 60 30

Vibratory and Combination Rollers

CC 222/222C and CC 232/232C
Work Shop Manual, Charge & Steering Pump
W1040EN2
This instruction apply from PIN (S/N)
CC 222: *61710222*, CC 222C: *61810222*
CC 232: *61910232*, CC 232C: *62010232*
Valid for charge & steering pump P/No:
35 89 93

We reserve the right to change specifications without notice.

Printed in Sweden.

Char
ge &
Charge
Steering Pump

CC 222/232/C

Charge & steering pump

W-1040-2 EN

Char
ge &
Charge
Steering Pump

Contents
Notes

Contents

Page

Charge and Steering Pump

Safety Regulations ................................................................................................................ 4-5
Introduction ............................................................................................................................ 6
Technical specifications .......................................................................................................... 7
Exploded view ......................................................................................................................... 8
Bushes and gear set ................................................................................................................. 9
Maintenance ........................................................................................................................... 10
Dismantling of pump ............................................................................................................ 10
Inspection and repair ............................................................................................................ 11
Re-asambling the unit ........................................................................................................... 12
Dismantling of the load sensing valve ................................................................................. 14
Running in ............................................................................................................................. 15

Notes
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CC 222/232/C Charge & steering pump

W-1040-2 EN

Safety Regulations

Char
ge &
Charge
Steering Pump

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.

CC 222/232/C

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W-1040-2 EN

Char
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Steering Pump

Safety Regulations
cont
d.
contd.

Start

When starting, all operating levers must be in neutral position.

Only start the machine from the drivers 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!

Electrical and hydraulic equipment

1. Personal safety must be observed when batteries are handled or tested.
2. A fully equipped medical kit, including eye-wash facilities, should be available
and protective clothing, including eye protection, should be worn.
3.
Acid splashes in the eye should be treated immediately with plenty of clean
water and neutralized with sodium bicarbonate solution.
4. Acid splashes on clothing must be treated with an alkali, such as ammonia, if
holes are to be avoided.
5.
A safety hazard exist during or after battery charging due to emission of a
highly flammable hydrogen gas. Any testing involving production of sparks, e.g.
electrical load test, must not be performed until the gas has dispersed from the
cell. A similar hazard occurs when a battery is fitted on to a vehicle immediately
after the battery has been removed from a charging plant.
6.
Hydraulic equipment is under high pressure.
Fluids (fuel, hydraulic oil) which escape under high pressure can penetrate the
skin and cause serious injury.
Therefor immediately consult a doctor if such injury occurs.
7.
Notice that failure on the hydraulic or electrical system may give the roller an
unpredictable and dangerous function.
CC 222/232/C Charge & steering pump

W-1040-2 EN

Intruduction

Char
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Charge
Steering Pump

Introduction to Charge & Steering Pump

Svedala Dynapac use a new load sensing gear pump as charge and steering pump in their
new CC 222 and CC 232. This new load sensing pump will enhance the efficiency and
performance of our modern rollers. The purpose of this manual is to provide you with
the informations necessary for the normal maintenance of the CC222/232/C Vibration
& Traction Pump from Svedala Dynapac Heavy.
Advantages
The load sensing function reduces wasted energy by providing flow to the priority
circuit only when required. In addition, the inherent mechanical and volumetric efficiency of this pump further reduce wasted energy.
Lower fuel consumption and longer operation between refuelling, is the operating benefit. Another benefit to be gained by using this pump is lower operating noise levels.
Function of the load sensing pump
The Load Sensing Pump utilizes an integral Load Sensing Priority Valve to split the
pump flow between the priority and excess flow circuits in response to the pilot or load
sensing signal. Flow is available from the priority port on demand and at a pressure
determined by the load sense signal. Flow from the priority port is proportional to the
requirements of the steering unit.
With this new steering pump, a small flow passes through the load sense pilot line.
When the steering is idle, this flow maintains the steering unit at system temperature to
help prevent thermal shock. Upon operation of the steering, a load sense pilot signal is
created within the hydrostatic steering unit and signals the pump to deliver the flow and
pressure required by the steering. When the steering is operated the dynamic load sense
supplies flow to the priority port to match the requirements of the steering. The system
also provide faster steering response.
As charge pressure to
to propulsion &
vibration pump.

Steering pressure.
Right.

Steering pressure.
Left.

Steering Unit

CC 222/232/C

Charge & steering pump

(Load Sensing).

Charge & steering pump

W-1040-2 EN

Char
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Steering Pump

Technical
Specifications

Technical Specifications
Priority flow rates of the flow dividers are held to close tolerances under all normal
operating conditions of pressure, fluid viscosity and temperature. Typical priority flow
tolerance is 10% at 13 litres/minute (3.5 US gpm) and 15% at 6 litres/minute (1,5 US
gpm).
As with other Svedala Dynapac products, quality and durability have been emphasized.
The pump section utilizes a high tensile extruded aluminium body, one piece hardened
steel gears and DU lined pressure die cast bushes.
The valve section uses high grade cast iron valve body and induction hardened steel
spool. These materials, along with accurate geometric conformance and surface finishes,
give a long component life and good resistance to cyclic pressure fatigue. Close control
of manufacturing tolerances minimizes leakage rates and ensures consistency of performance.

Typical performance applicable when using ISOVG 32 at 40C (104F)

Theoretical Displacement cm3/rev (cu inches /rev)

19,5

(1.19)

Delivery at 2800 rpm (v=100%) at CF l/min (gal/min)

55

(14.52)

Maximum Continuos Pressure CF MPa (psi)

25

(3625)

CC 222/232/C Charge & steering pump

W-1040-2 EN

Exploded Vie
w
View

Char
ge &
Charge
Steering Pump

Exploded view

CC 222/232/C

Charge & steering pump

W-1040-2 EN

Char
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Charge
Steering Pump

Gear set

Arrangement of bushes and gear set in body

CC 222/232/C Charge & steering pump

W-1040-2 EN

Dismantling

Char
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Charge
Steering Pump

Dismantling, maintenance, re-assembling & running in

Routine maintenance
Except of cleaning/changing filter (21) once in a year, no maintenance is necessary other
than periodic checks for tightness of the mounting bolts and port fittings plus visual
examination for oil leaks. The unit should be kept externally clean, especially in the area
of the shaft seal as dirt can accelerate seal wear and cause leakage.
Direction of rotation
The direction of rotation is indicated by the word ROTATE and an arrow etched on the
body adjacent to the driveshaft. Rotation is always specified as viewed on the driveshaft.
For identification the inlet port is also arrowed
and marked inlet.
Dismantling the unit
1 . Before starting work ensure that the unit, work area and all tools are throughly
clean to prevent contamination entering the unit. Plug all open hoses on the roller.

10

2.

Remove bolts and spring washers (33 and 32).

3.

Remove end cover (3), bodyOring (4), bush seal and back-up seal (5 and 6).

4.

Turn the unit over and lightly tap the mounting flange cover (12) to disengage it
from the locating dowels and slide the flange squarely off the shaft.

5.

Remove retaining ring (36) and push the shaft seal (13) squarely out of the mounting flange taking care not to damage any sealing surfaces.

6.

Remove bodyOring (4), bush seal and back-up seal (6 and 5).

7.

Before removing the internal components mark the bushes to denote the location
in the body. On a plain area away from seal location mark.

FD =
FI =
CD=
Cl =

Bush on driveshaft flange end

Bush on driven gear flange end
Bush on driveshaft cover end
Bush on driven gear cover end

8.

With the unit lying on its side hold the driveshaft (10) and pull it squarely out of
the body bringing with it the bushes (7 and 8).

9.

Remove driven gear (10) and the two remaining bushes.

CC 222/232/C

Charge & steering pump

W-1040-2 EN

Char
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Steering Pump

Inspection

Inspection and repair

Assessment
Each component should be thoroughly cleaned, carefully examined and assessed for
suitability of re-use. Below is a guide for inspecting the various components.
Body
Inspect the body bore cut-in where gears wipe into the body.
The body can only be re-used if the cut-in is bright and polished in appearance and the
depth does not exceed .08 mm.
The body should be replaced if the surface is scored, has a matt appearance or shows
signs that the tip of the gears have dug in and torn away the surface material.
The body should be inspected to ensure that there is no superficial damage which may
adversely effect performance or sealing. Pay particular attention to the port threads and
body O ring seal recesses.
Mounting Flange Cover and End Cover
The inner surfaces should be inspected to ensure that there is no unusual wear or scoring
in the regions where the body 0rings and bush seals contact, which could
result in external leakage.
Check the shaft seal recess for scoring or damage that could resist in oil leakage around
the outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite
hydraulic sealant to overcome slight damage in this area.
Bushes
The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading
against the gear side faces, which is often more pronounced on the low pressure side.
These should be replaced if there is any general scoring or fine scoring with a matt appearance or tearing of the surface material.
Often there is a witness where the tips of the opposing gears have wiped an overlap
resembling a half moon shape. There must be no noticeable wear step as it is critical that
the bush side face is completely flat to the gear side face.
The bush bearing liners are acceptable providing that they are not scored or show other
damage. The general outside area of the bush should not show any prominent signs of
wear.

CC 222/232/C Charge & steering pump

W-1040-2 EN

11

Inspection

Char
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Charge
Steering Pump

Gears
The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by
drawing a sharp pointed tool across the surface from the journal outwards towards the
tip of the gear, then the gear is unserviceable.
The gear teeth should then be carefully examined to ensure that there are no signs of
bruising or pitting.
The journal bearing surfaces should be completely free from scoring or bruising. The
surface should appear highly polished and smooth to touch.
Examine the area where the shaft seal lips run on the driveshaft, this shows up as a polished ring or rings. If a noticeable groove can be felt or there is scoring the shaft should
be replaced.
Provided the driveshaft is not damaged from the drive coupling and the gears have not
been harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched set.
As a matter of good practice, when pumps have been dismantled, all the seals should be
replaced. It is most important that only the genuine Dynapac seals are used.

12

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Charge & steering pump

W-1040-2 EN

Char
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Steering Pump

Re-Assembling
the pump

Re-Assembling the pump

Ensure all parts are perfectly clean and lubricate bushes and gears with clean hydraulic
fluid (ensure 0 ring recess and end faces of body remain dry). This will assist assembly
of components into the body bores.
1.

Refit cover end bushes (CD and Cl) into the undowelled end of the body from
where they were removed. TheCshape cut-out in the bushes must be to the side
of the body with the cusp removal flat (see page 9).

2.

Place the end cover (3) against the undowelled end of the body (9) and stand the
assembly on the cover so the dowels are uppermost and to the left hand side.

3.

Fit driveshaft (10) and driven gear (11) into their original positions in the body.

4.

Re-fit flange end bushes (FD and FI) into their original bores remembering the C
cut-out must be to the side of the body with the cusp removal flat and match the
cover end bushes.

5.

Fit new body 0 ring (4), bush seal and back-up seal (5 and 6) ensuring that the
seals locate correctly in the seal grooves.

6.

Fit new shaft seal (13) into the recess in the mounting flange with the garter
spring facing into the pump. Refit circlip (36) in groove. Remember that if the seal
recess was scored then Loctite hydraulic sealant must be applied to the outer diameter of the seal. Apply a coat of high melting point grease to the shaft seal lips.

7.

Fit the shaft seal assembly sleeve, supplied in seal kit over driveshaft and carefully
refit mounting flange cover (12) ensuring that it locates squarely onto the dowels in
the body - remove assembly sleeve.

8.

Holding the whole unit together carefully turn it over but ensuring it is supported
on the mounting flange cover and not the driveshaft.

9.

Remove end cover (3) and fit new body Oring (4), bush seals and back-up seals
(5 and 6).

10.

Replace the end cover and refit bolts and spring washers. Torque tighten bolts to
46-51 Nm (34-38 lbft).

11.

Pour a small amount of clean hydraulic fluid into a port and check that the shaft
can be rotated without undue force using a smooth jawed vice.

CC 222/232/C Charge & steering pump

W-1040-2 EN

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Load Sensing V
alv
e
Valv
alve

Char
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Steering Pump

Dismantling the Load Sensing Valve

1.

Before commencing work the valve must be cleaned externally to remove all accumulations of dirt that could enter the unit on dismantling.

2.

Remove valve from pump.

3.

Remove spool plug (14) and spring seat (18) allowing spring (17) and spool (16) to
be removed. Examine spool and bore for signs of damage. Remove 0 rings (15)
and (19) and replace with new.

4.

On this valves with load sensing, spring seat (18) has a 0.7mm orifice in the base
of the spring recess. It is important that this orifice is clear and free from contaminant. The spool also have a 0.7mm orifice in the top face, this must also be free
from contaminant.

5.

There is also an internal filter (21) which should be changed at service intervals.
Normally it's enough to change the internal filter during the yearly maintenance.

To change filter (21) unscrew damping orifice (22) from bottom end of spool by holding
spool on the unground surface to prevent damage. Remove filter (21) and replace with
new one. Apply a small amount of loctite 542 to threads of damping orifice (22) and
screw in to hold filter in place, torque tighten to 14 Nm (1 0 lbft).

14

6.

Remove core plug (31) to obtain access to Relief Valve seat (25). Unscrew Relief
Valve seat. N.B. This item is peened in position and it may be necessary to locally
drill to ease removal.

7.

Remove Core plug (31), Screw (30), O-ring (29), Strainer filter (28), Relief Valve
seat (25), valve (24) and spring (23). Inspect for signs of wear or damage.
RemoveOrings (26), (27) and (29) and replace with new.

8.

Prior to re-assembly thoroughly clean all components.

9.

Replace Relief Valve components ensuring valve remains located in valve seat.
Screw in Relief Valve seat to just take up spring load. Relief Valve pressure will
require setting on the application or test rig.

10.

Replace spool, spring and spool plugs, torque tighten plugs (18) to 100-105 Nm
(74-78 lbft) and (14) to 75-80 Nm (55-59 lbft).

11.

Refit valve to pump ensuring inlet to valve in rear face is over high pressure side of
pump (semi-circular cut out in bushes).

CC 222/232/C

Charge & steering pump

W-1040-2 EN

Char
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Charge
Steering Pump

Load Sensing V
alv
e
Valv
alve

12.

Torque tighten bolts, to 46-51 Nm (34-38 lbft).

13.

If new components have been fitted to the pump, then it must be run in (see section Running In).
To do this with the valve fitted the relief valve must be screwed in solid, the main
spool and spring removed, but cap replaced. Blank port P and load sense connection, and fit rig loading circuit to Port EF.
Run into 1.5 MPa below the maximum pressure 24 MPa. After running in refit
main spool (16), spring (17) and unscrew relief valve ready for resetting.

14.

Resetting Relief Valve - with pump valve unit in application or on test rig fit pressure gauge and variable restrictor to line from valve port P for flow dividers.
(Gauge must be between restrictor and valve port.) On load sensing valves connect
the load sense port to the line from Port P between the valve and variable restrictor
to ensure flow is demanded from Port P.
Run pump at normal operating speed close restrictor and adjust valve pressure
setting by screwing in/out relief valve seat until correct level is reached.

15.

Peen valve seat in position using a centre punch to prevent movement in service.
Finally fit new core plug (31).

Running in
A unit which has been re-assembled with either new gears, bushes or body, must be
carefully run-in before it is subjected to full working conditions.
Ideally this should be done on a test rig (see page 9) where pressure can be gradually
applied and any wipings from the body cut-in arrested by filters.
It is recommended that the unit is run-in at 1500 rpm, initially, at zero pressure for one
minute then in stages with the pressure increased by 35 bar every minute, until maximum rated pressure has been attained. Frequently check the system temperature, ensuring that it does not exceed the maximum permissible figure of 80C. lf the temperature
exceeds the system or unit specification the test must be delayed and operated off-load
until acceptable temperatures are obtained.

CC 222/232/C Charge & steering pump

W-1040-2 EN

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