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5018 PDS 2003 E .pdf link .pdf



Nom original: 5018_PDS_2003_E.pdf-link.pdf
Titre: WP Suspension manual Engels
Auteur: Pierre Pince van der Aa

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Taille du document: 4.9 Mo (99 pages).
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Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Shock absorber 5018 PDS 2003

05/2002

Shock absorber

5018 PDS 2003
Introduction
Exploded view
Disassembly shock absorber
Disassembly tube side
Disassembly MCC
Assembling MCC
Assembling Tube side
Disassembly piston-rod side
Diassembly adaptor DU-bush
Assembling adaptor DU-bush
Assembling piston-rod side
Assembling shock absorber
Bleeding
On pressure with nitrogen
Mounting spring
Adjustment

2
3
4
13
33
39
44
53
63
67
70
81
87
92
95
98
1

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Introduction
General notice
Pay attention to the following notes, when you are working
with WP suspension products as described in this
workshop manual:
Always use clean and professional tools.
Regular you need next to the general equipment, the
special tools of WP Suspension.
These tools with a unique “T” number (available at
WP Suspension) protect you from damaging the parts.
Always use aluminium protector-plates, when clamping our
products or parts in the vice.
Always replace damaged or worn parts.

Shock absorber 5018 PDS 2003

05/2002

Clean all parts before assembling.
Caution:
Many times it is necesarry to assemble parts with T131,
T132 and T163.
These parts must dry for at least four hours!!

We r k p l a a t s h a n d b o e k

2

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Shock absorber 5018 PDS 2003

05/2002

Exploded view

3

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Disassembly Shock
absorber
Take note of the rebound (REB) position.
Fully closed is turning the adjustment
screw (“+”) clockwise.

MCC
MCC = Mono Compression Control

Shock absorber 5018 PDS 2003

05/2002

Take note of the compression (COM)
position.
Fully closed is turning the adjustment
screw (“+”) clockwise.

DCC
DCC = Dual Compression Control
Take note of the compression
Low-Speed position.
We r k p l a a t s h a n d b o e k
Fully closed is turning the adjustment
screw clockwise.

4

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

DCC
Take note of the compression
High-Speed position.
Fully closed is turning the hexagonal (size
17) screw clockwise.

Shock absorber 5018 PDS 2003

05/2002

Measure the length of the spring.
Spring preload.

Unscrew the Allen bolt (size 4).

We r k p l a a t s h a n d b o e k

5

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Release the spring preload with open
spanner T106.

Shock absorber 5018 PDS 2003

05/2002

Screw the screw retainer against the lock
retainer.

Disassemble the spring retainer and
springring.

We r k p l a a t s h a n d b o e k

6

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Remove the washer.

Shock absorber 5018 PDS 2003

05/2002

Remove the spring.
Pay attention to the assembling
direction!!!

Remove the second washer.

We r k p l a a t s h a n d b o e k

7

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Shock absorber 5018 PDS 2003

05/2002

Spring with washers, spring retainer and
springring.

We r k p l a a t s h a n d b o e k

8

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Disassemble the rubber cap.

Shock absorber 5018 PDS 2003

05/2002

Unscrew slowly the nitrogen plug (size 4)
to release the pressure.

Nitrogen plug with O-ring.

We r k p l a a t s h a n d b o e k

9

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Tap the cap from the tube.

Shock absorber 5018 PDS 2003

05/2002

1. Place disassembling bush T1216 on
the adaptor DU-bush.

2.

We r k p l a a t s h a n d b o e k

10

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Push the adaptor DU-bush downwards.

Shock absorber 5018 PDS 2003

05/2002

Disassemble the springring out of the
tube.

Springring.

We r k p l a a t s h a n d b o e k

11

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Shock absorber 5018 PDS 2003

05/2002

Pull carefully but firmly the piston-rod
“complete” out of the tube.

Push with depth-stop T107S the
separation piston downwards.

We r k p l a a t s h a n d b o e k

12

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Disassembly tube-side
Drain the oil out the tube.

Shock absorber 5018 PDS 2003

05/2002

Clamp the tube side in the vice.

Remove the springring out of the groove
and slide it a little bit downwards.

We r k p l a a t s h a n d b o e k

13

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Slide the guiding bush downwards.

Shock absorber 5018 PDS 2003

05/2002

Remove the upper springring.

Remove the guiding bush.
Pay attention to the assembling
direction!!!
We r k p l a a t s h a n d b o e k

14

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Remove the springring.

Shock absorber 5018 PDS 2003

05/2002

Spring guiding bush with the two
springrings.

We r k p l a a t s h a n d b o e k

15

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Turn the screw-retainer of the tube.

Shock absorber 5018 PDS 2003

05/2002

Screw-retainer with the Allen bolt.

We r k p l a a t s h a n d b o e k

16

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Unscrew the screw-cap of the MCC
(size 24)
(DCC also size 24)

Shock absorber 5018 PDS 2003

05/2002

Remove the screw-cap.

Remove the washer inside the screwcap, or on top of the spring inside the
bottom.
We r k p l a a t s h a n d b o e k

17

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Remove the spring.

Shock absorber 5018 PDS 2003

05/2002

Pull the damping holder “cpl” out of the
bottom.

Srew-cap with adjustment needle,
spring and the MCC damping holder
“cpl”.
We r k p l a a t s h a n d b o e k

18

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Heat the lock retainer.

Shock absorber 5018 PDS 2003

05/2002

Unscrew the lock retainer with open
spanner T1233.

Screw the lock retainer of the bottom.

We r k p l a a t s h a n d b o e k

19

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Heat the bottom near the tube.

Shock absorber 5018 PDS 2003

05/2002

Use slide-spanner T146 with bush T1201.

Unscrew the tube.

We r k p l a a t s h a n d b o e k

20

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Screw the tube out of the bottom.

Shock absorber 5018 PDS 2003

05/2002

Screw the lock retainer of the tube.

Tube with lock retainer.

We r k p l a a t s h a n d b o e k

21

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Disassemble the O-ring out of the groove
inside the bottom.

Shock absorber 5018 PDS 2003

05/2002

Place dis- / assembling tool T145S on
top of the screw-cap

Place pin spanner T125S onto T145S.

We r k p l a a t s h a n d b o e k

22

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Heat the reservoir near the bottom.

Shock absorber 5018 PDS 2003

05/2002

Unscrew the screw-cap.

Turn the reservoir from the bottom.

We r k p l a a t s h a n d b o e k

23

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Remove the O-ring.

Shock absorber 5018 PDS 2003

05/2002

Bottom “cpl” with both O-rings.

We r k p l a a t s h a n d b o e k

24

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Pay attention to the assembling
direction!!!
Push the separation piston out of the
reservoir.

Shock absorber 5018 PDS 2003

05/2002

Separation piston.

Disassemble the O-ring.

We r k p l a a t s h a n d b o e k

25

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Shock absorber 5018 PDS 2003

05/2002

Separation piston, piston ring and O-ring.

We r k p l a a t s h a n d b o e k

26

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Clamp the bottom in the vice.

Shock absorber 5018 PDS 2003

05/2002

Use disassembling tool T120 for
disassembling the adaptor bushes.

Tap the adaptor bush out of the heimjoint.

We r k p l a a t s h a n d b o e k

27

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Remove the seal.

Shock absorber 5018 PDS 2003

05/2002

Disassemble the springring.

Tap the other adaptor bush out of the
heim-joint.

We r k p l a a t s h a n d b o e k

28

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Use Dis- / assembling tool T1207S for
disassembling the heim-joint.

Shock absorber 5018 PDS 2003

05/2002

Press the heim-joint out of the bottom at
the side were the springring is removed.

Adaptor bushes, seals, springrings and
heim-joint.

We r k p l a a t s h a n d b o e k

29

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Replace one springring.

Shock absorber 5018 PDS 2003

05/2002

Assemble the heim-joint with the
bevelled edge into the direction of the
bottom with assembling tool T1206.

Press the heim-joint into the bottom with
support of the vice.

We r k p l a a t s h a n d b o e k

30

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Press with T1207(A) the heim-joint
against the springring.

Shock absorber 5018 PDS 2003

05/2002

Assemble the springring into the groove.

Replace the seals.

We r k p l a a t s h a n d b o e k

31

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

1. Assemble the adaptor bushes with
support of T1206.

Shock absorber 5018 PDS 2003

05/2002

2.

We r k p l a a t s h a n d b o e k

32

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Disassembly MCC
There is a separated workshop
manual for the DCC.
----------------------------------------------------Damping holder MCC.

Shock absorber 5018 PDS 2003

05/2002

Remove the disk.
Pay attention to the assembling
direction!!!

Clamp the damping holder with
clamping block T1202S. Not too tight!

We r k p l a a t s h a n d b o e k

33

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Unscrew the nut (size 10).

Shock absorber 5018 PDS 2003

05/2002

Turn the nut of.

Remove the piston with check-valve.

We r k p l a a t s h a n d b o e k

34

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Piston with the check-valve side.

Shock absorber 5018 PDS 2003

05/2002

Compression side.

Damping holder with shims (setting).

We r k p l a a t s h a n d b o e k

35

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Remove the shims of the damping holder.
Pay attention to the assembling order and
direction!!!

Shock absorber 5018 PDS 2003

05/2002

- Nut M6
- piston with check-valve
- setting (shims)
- damping holder
- disk.

We r k p l a a t s h a n d b o e k

36

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Remove the O-ring of the screw-cap.

Shock absorber 5018 PDS 2003

05/2002

Turn clockwise the adjustment needle
out of the screw-cap.

Adjustment needle “complete”.

We r k p l a a t s h a n d b o e k

37

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Shock absorber 5018 PDS 2003

05/2002

- Steel ball
- spring
- adjustment needle with O-ring
- screw-cap
- O-ring

We r k p l a a t s h a n d b o e k

38

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Assembling MCC
Assemble the spring and steel ball, and
grease, also the O-ring, these with water
proof grease T159.

Shock absorber 5018 PDS 2003

05/2002

Assemble the O-ring.

Assemble the needle.

We r k p l a a t s h a n d b o e k

39

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Turn the needle fully open.

Shock absorber 5018 PDS 2003

05/2002

Replace the setting and piston with the
check-valve

Wet the thread of the nut with Loctite
2701 (T132) and turn the nut on the
holder.
We r k p l a a t s h a n d b o e k

40

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Tighten the nut to a torque of 6Nm.

Shock absorber 5018 PDS 2003

05/2002

Replace the disk.

We r k p l a a t s h a n d b o e k

41

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Assembling tube side
Assemble the O-ring on the bottom.

Shock absorber 5018 PDS 2003

05/2002

Assemble the O-ring inside the bottom.

Grease the O-ring groove of the
separation piston with O-ring grease
T158.
We r k p l a a t s h a n d b o e k

42

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Assemble the O-ring.

Shock absorber 5018 PDS 2003

05/2002

Grease the O-ring with T158.

Pay attention to the groove of the
nitrogen reservoir.

We r k p l a a t s h a n d b o e k
“groove”.

43

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

1. Assemble the separation piston and
piston ring with the hollow surface into the
reservoir at the groove side.

Shock absorber 5018 PDS 2003

05/2002

2.

Push the separation piston into the
reservoir.

We r k p l a a t s h a n d b o e k

44

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Wet the thread of the bottom with T132.

Shock absorber 5018 PDS 2003

05/2002

Wet the thread of the reservoir with
T132 on both sides.

Wet the thread of the screw-cap.

We r k p l a a t s h a n d b o e k

45

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Turn the reservoir with screw-cap on the
bottom.

Shock absorber 5018 PDS 2003

05/2002

Tighten the reservoir wit T125S and
T145S.

Wet the thread inside the bottom with
T132.

We r k p l a a t s h a n d b o e k

46

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Turn the lock retainer as far as possible
onto the tube.

Shock absorber 5018 PDS 2003

05/2002

Wet the thread of the tube with T132.

Turn the tube into the bottom.

We r k p l a a t s h a n d b o e k

47

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

Tighten the tube with T146 and T1201.

Shock absorber 5018 PDS 2003

05/2002

Screw the lock retainer against the
bottom and tighten it with T1233.

Turn the screw spring retainer onto the
tube and...

We r k p l a a t s h a n d b o e k

48

Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling

...completely downwards.

Shock absorber 5018 PDS 2003

05/2002

Assemble the springring passed the
groove of the tube.

Slide the spring guide onto the tube.

We r k p l a a t s h a n d b o e k

49


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