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General Instructions Know-How Values Tests Tools Parts PCI-SB
Brake Valving Torque module Bearing support Options -
About this document MS

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.
Structure of document
This document is composed to different sections:

• Section “General”
Contains general instructions on the document use, safety information, product identification...
• Section “Instructions”
Contains complete operating instructions to disassemble and reassemble each sub-assembly of products
explaining the different technologies mounted on it. These operating instructions include references to
sections “Know-How”, “Values”, “Tests”…
• Section “Know-How”
Contains instructions with tricks to do operations requiring use of specific tool or a particular knack. This
section will be used by neophyte technicians to learn the repair work or by experienced technicians desirous
to reinforce their knowledge on the best practices.
• Section “Values”
Contains tables of values used during the operating instructions as the shimming values, forces values, rotary
torques values, number of parts to install…
• Section “Tests”
Contains the operating instructions to check the product operation before or after repair work.
• Section “Tools”
Contains information and drawings to purchase commercial tools or manufacture specific tools.
• Section “Parts”
Contains generic spare parts list illustrated with exploded views.
• Section “PCI-SB”
Contains service bulletins used to explain products evolutions with the aftermarket impacts (dimensions,
interchangeability, spare parts…).
These different sections are divided in sub-sections representing the sub-assemblies of products.
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.
21-APR-2010 © Poclain Hydraulics, 2010 ALL-GE-0000-01-EN-A – 001

MS About this document
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.
Know-
H
ow
Reference to section “Know-How”.

ow
H
Know-
Xxxxxxxx Xxxxxx Xx xxxx Xxxxxxx Xxxxxx
Xxxxx xxxxxx Xxx xxxx Xxx xxxx
Xx xxxxxxx Xxx xxxx Xxx xxxx Xxx xxxx
Xx xxxxxxxx
Xxxxxx
Xxxxx xxxxxx
Xxx xxxx xxx
Xxxxxxx xxx
Xxx xxxx
Xxx xxxx
Xxx xxxx
Xxx xxxx
Xxx xxxx
Xxx xxxx
Xxx xxxx
Xxx xxxx
Xxx xxxx
Xxx xxxx
Xxx xxxx
Reference to section “Value”.
Xx xxxxxx Xxx xxxx Xxx xxxx
Reference to one or a list of tools.
Reference to section “PCI-SB”.
Reference to other document.
Copyright
© Poclain Hydraulics, 2010.

The Poclain Hydraulics brand is the property of Poclain Hydraulics S.A.
This document as well as the instructions, the technical data, the know-how, the illustrations and other
information set forth in it are the property of Poclain Hydraulics. It is strictly confidential. It must not be used,
duplicated, copied or disclosed to a third party in full or in part without our prior written consent.
In accordance with its policy of continuous improvement, Poclain Hydraulics reserves the right to modify the
specifications and drawings described herein without prior notice.
ALL-GE-0000-01-EN-A – 002 © Poclain Hydraulics, 2010 21-APR-2010

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Cylinder-block repair MS
Contents of instructions
Components identification
Pistons
Lunambules
Piston rings
Repair of cylinder-block with side clips
Repair of cylinder-block with radial clips
20-MAY-2010 © Poclain Hydraulics, 2010 MS-IN-3000-01-EN-A – 001

MS Components identification
Pistons
Straight piston Stepped piston
ØD ØD
7142 7143
Diameter ØD
Motor Type of piston Class 0 Class 1 Execution
mm [in] mm [in]
MS02 Straight 24,8 [0.976] 24,9 [0.980]
MSE02 Stepped 31 [1.220] 31,1 [1.224]
MS03 Straight
MSE03 Stepped
33,3 [1.311] 33,4 [1.314]
MS04 Straight
MS05 Straight
MSE05 Stepped 38,5 [1.516] 38,6 [1.520]
L1, R1
MS08 Straight 33,3 [1.311] 33,4 [1.314]
MSE08 Stepped 38,5 [1.516] 38,6 [1.520]
MS11 Straight 43,2 [1.701] 43,3 [1.705]
MSE11 Stepped 50 [1.969] 50,1 [1.972]
MS18 Straight 43,2 [1.701] 43,3 [1.705]
MSE18 Stepped 50 [1.969] 50,1 [1.972]
MS25 Straight 58 [2.283] 58,1 [2.287]
MS35 Straight 43,2 [1.701] 43,3 [1.705]
MS50 Straight L2, R2
MS83 Straight 58 [2.283] 58,1 [2.287]
MS125 Straight R3
Cylinder-block rows
Type of clip
1 2 3
Side (L)
Only available in N/A
aftermarket
Radial (R)
MS-IN-3000-01-EN-A – 002 © Poclain Hydraulics, 2010 20-MAY-2010

Components identification MS
What is class 1?
x Bigger diameter: ØD1 = ØD + 0,1 mm [0.004 in]
1 x Identification: number “1” marked on the bottom of piston
an on lateral face of cylinder-block next to the big bore.
ØD1 x Possible presence of several pistons class 1 on the same
ØD1 cylinder-block.
x No special pattern.
Never fit standard piston into a cylinder-

block bore class 1.
ØD 1
Technology now obsolete and no longer

available from aftermarket.
If piston class 1 must be replaced, change
the complete cylinder-block assembly.
7600
Lunambules
x Lunambule with plane base:

Only available in aftermarket.
x Lunambule with circular base

MS Components identification
Piston rings
x Cast iron piston ring with large cut
x Plastic piston ring with large cut and face groove
x Plastic piston ring with small cut and face groove
x Plastic piston ring with no cut and face groove

Repair of cylinder-block with side clips MS

Disassembly
x Remove the cylinder-block (3005) from a motor

shaft.
Know-
Ref.: MS-KH-3000-01-EN,
Ho
w
w
Cylinder-block removal.
Ho
Know-
x Remove the side clips (3070) and discard them.
Know-
Ref.: MS-KH-3000-02-EN,
Ho
w
w
Clips and pistons removal.
Ho
Know-
x Extract all pistons (3030) from the cylinder-block.
Assembly
x Insert bushing (3035) into pistons.

x Lubricate rollers (3040) with hydraulic oil and insert
into pistons.
x Place lunambules (3060) on each side of the rollers
and insert all subassemblies into theirs bores. Pay
attention for proper orientation before pressing each
piston.
x Assemble the side clips (3070) on a cylinder-block.
It is mandatory to assemble the

side clips with the special tool,
P/N 000044689A.
Know-
Ref.: MS-KH-3000-03-EN,
Ho
w
w
Clips installation.
Ho
Know-
Ref.: TO-3000-002-001
See the manual of optional tooling,
P/N A25961T.

MS Repair of cylinder-block with radial clips
Disassembly
x Remove the cylinder-block (3005) from a motor

shaft.
Know-
Ref.: MS-KH-3000-01-EN,
Ho
w
w
Cylinder-block removal.
Ho
Know-
x Remove the side clips (3070) and discard them.
Know-
Ref.: MS-KH-3000-02-EN,
Ho
w
w
Clips and pistons removal.
Ho
Know-
x Extract all pistons (3030) from the cylinder-block.
Assembly
x Insert bushing (3035) into pistons.

x Lubricate rollers (3040) with hydraulic oil and insert
into pistons.
x Place lunambules (3060) on each side of the rollers
and insert all subassemblies into theirs bores. Pay
attention for proper orientation before pressing each
piston.
x Assemble the radial clips (3070) on a cylinder-block.
x Make sure that a gap between the clips and cylinder-
block outside diameter is < 0,2 mm [0.008 in].
Repositioning the clip after

mounting is not permitted. If the
clip is not rightly locked, it must
be discarded and a new clip
must be installed..
It is mandatory to assemble the

radial clips with the special tool
according to the type of motor.
Know-
Ref.: MS-KH-3000-03-EN,
Ho
w
w
Clips installation.
Ho
Know-
Ref.: TO-3000-004-001, 002, 003,

004 and 005.
See the manual of base tooling,
P/N A06585H.

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Brake Valving Torque module Bearing support Options -

About this document MS

These operating instructions should be read and studied

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21-APR-2010 © Poclain Hydraulics, 2010 ALL-GE-0000-01-EN-A – 001

Brake Valving Torque module Bearing support Options -

MS About this document

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