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1. 5 Tap the expander pin part 73 into cam ring hole Insert the lubricated o ring part 116 into the cylinder housing groove 6 Mount the cam ring into the rear cover align the pin into its hole tighten evenly either with a press or with four casing bolts Make sure that the expander pin doesn t protrude through the cam ring 10 Distribution valve 1 Place the lubricated sealing rings part 59 into their grooves on the support ring part 60 2 Lubricate the seal surface of the distribution valve and place the support ring onto the distribution valve osa 50 3 Insert two pins part 57 into the holes on the distribution valve Santasalo Hydraulics Oy 46 Service manual to BBC serie 11 Hub cover 1 If the old outer bearing race has been removed press a new one part 81 into the hub cover part 80 Instal inner bearing race 2 Insert a lubricated o ring part 116 into the hub cover groove 12 Re assembly 1 Place the assembled rear cover onto the shaft Carefully tap the inner bearing race tightly against the wear ring of the shaft seal NOTE Beware of the sealing ring grooves on the shaft 2 Place three sealing rings parts 51 52 and 53 onto the grooves on the shaft 4 Lubricate the sealing rings parts 51 52 and 53 as well as the seal surface inside the distribution valve Position the sealing rings carefully in the center of the shaft 5 Carefully lift
2. hub cover with inner race of the bearing by evenly tightening the bolts Santasalo Hydraulics Oy Service manual to BBC serie 5 You should not remove the outer bearing race from the hub cover unless the bearing is being replaced 6 Remove the o ring part 116 from its groove 4 Dismantling the cylinder block 1 Pry out the retainer ring part 44 using a screwdriver Detach the retainer ring halves part 37 which are holding the cylinder block part 25 2 Carefully lift off the cylinder block part 25 from the shaft with two screwdrivers NOTE If the distribution valve part 50 is 44 detached with the cylinder block take care not to drop the distribution valve during removal 3 Detach the distribution valve part 50 The distribution valve will lift off its seals If necessary lift the rear cover part 65 upwards with a strong jerk or lift the cover and tap the shaft end with a rubber mallet 4 Do not remove the distribution valve caps part 57 unless they are damaged 5 Dismantle the distribution valve only if excessive wear is observed Remove the support ring part 60 from the distribution valve Remove the sealing ring part 59 from the support ring Santasalo Hydraulics Oy a Service manual to BBC serie 6 Removing freewheeling mechanism optional Unscrew the freewheeling mechanism fastening screws part 43 Watch out for releasing springs Loosen
3. part 43 through the U plates and spacer sleeves and turn into place Tighten the screws 9 Rear cover 1 If the old rotating unit for the distribution valve has been removed insert the springs part 58 into the holes found in the rear cover place the connecting ring part 55 on top of the springs and tap the drive pins part 56 into the rear cover holes NOTE Use new drive pins 2 If the old outer bearing race has been removed press the new outer bearing race into the rear cover Install inner bearing race part 65 into the rear cover 3 Install the shaft seal part 67 into the rear cover with the open side of the seal facing the inside of the motor Press until the shaft seal lines up with the shoulder inside the rear cover Santasalo Hydraulics Oy Gs Service manual to BBC serie 3 1 Models where the shaft seal is installed Into support ring Push the shaft seal part 67 against the support ring part 68 with open side of the seal facing the inside of the motor Use Loctite 542 sealant on the outside of the seal Place a lubricated o ring part 72 onto the support ring groove Place the assembled support ring part 68 into the rear cover press until the shaft seal lines up with the shoulder inside the rear cover part 70 Ensure that the locking pin is in line with support ring hole 4 Insert the retainer ring part 69 into its groove Apply waterproof lubricant to the shaft seal lip
4. 21 are not in all models Remove the seal rings part 35 from the shaft only if damage is observed Santasalo Hydraulics Oy 9 Service manual to BBC serie BI ACK Z BRUIN Remove the plugs parts 15 and 162 using an allen key as well as caps parts 16 and 163 springs E j 16 parts 17 and 161 and valves FAN i df parts 18 and 160 Check the sealing N j surface of the case pressure valve 15 illi 160 and the filling valve je he 161 162 Santasalo Hydraulics Oy hio Service manual to BBC serie CLEANING AND INSPECTION OF THE PARTS NOTE Clean all parts thoroughly Inspect the following points very carefully The oil distribution surfaces of the distribution valve and the cylinder block must be unmarked and smooth The rolling surface of the cam ring and cam rollers must be unmarked and smooth Piston insert surface must be unmarked and smooth Cylinder surfaces and pistons must be faultless The 2 speed spool surface must be unmarked The cylinder block poppet spool must be undamaged and smooth N NOTE Use new seals for reassembling Santasalo Hydraulics Oy K Service manual to BBC serie MOTOR ASSEMBLING 7 Shaft 1 Place the oiled o ring part 3 onto the shaft groove If needed heat the shaft seal collar part 2 to a temperature of about 80 C 176 F Tap the collar part 2 onto the shaft 2 Installation of the 2 spee
5. BBC serie Service and maintenance manual Motor with brake Santasalo Hydraulics Oy PO Box 633 40101 Jyv skyl Finland Tel 358 2048 4130 fax 358 2048 4131 i F Sa nta salo e mail info hydraulics santasalo com http www santasalohydraulics com Ameria of Markan opr Service manual to BBC serie TABLE OF CONTENTS MOTOR DISMANTLING 1 Before dismantling 3 2 Dismantling the brake 3 3 Hub cover and bearing detachment 4 4 Dismantling the cylinder block 6 Removing freewheeling mechanism 7 optional Dismantling poppet spool optional 7 5 Dismantling rear cover 8 6 Dismantling the shaft 9 Dismantling 2 speed parts optional 9 CLEANING AND INSPECTION OF THE PARTS 11 MOTOR ASSEMBLING 7 Shaft 12 8 Cylinder block 14 Poppet valve installation optional 14 Freewheeling mechanism installation 14 optional 9 Rear cover 15 10 Distribution valve 16 11 Hub cover 17 12 Re assembly 17 13 Brake reassembly 22 14 After assembly 23 MAINTENANCE 15 Recommended oil 24 16 Spare parts 25 Santasalo Hydraulics Oy a Service manual to BBC serie MOTOR DISMANTLING 1 Before dismantling Remove the motor from the system and plug the oil connections Clean the motor externally Where possible test run the motor on the test bench in order to determine any hydraulic system related faults NOTE When testing motors with multi disc brakes make sure that the wheel attachment bolts are p
6. Bearing tightening values Nm 13 Remove the retainer ring halves from the shaft groove and loosen the press tool 13a Models with shims Position the required quantity of the shims part 84 between the bearing and the retainer ring halves recorded gap C1 0 1 0 2 mm 0 004 0 008 Place the thickest shims against the retainer ring halves and the bearing Pre tighten the bearing applying force by tightening the tension screw See table 9 pretightening 13b Models without shims Select retainer ring halves with thicknes of recorded gap C1 0 1 0 2 mm 0 004 0 008 Pre tighten the bearing applying force by tightening the tension screw See table 9 pretightening 14 Lubricate the shims and retainer rings thoroughly prior to installation Ensure that the retainer ring halves do not contain sharp edges Position one half of the retainer ring part 82 onto the shaft groove Strike the center of the retainer ring halve with a special tool until it begins to expand at the sides Following this tap the other half of the retainer ring halve onto the groove Tap moving from one end of the ring to the other until the retainer ring half reaches the bottom of the groove Santasalo Hydraulics Oy Service manual to BBC serie 15 With the first half of the retainer ring in place loosen and remove the hub bearing press tool Position the other half of the retainer ring into its gro
7. c spring or springs part 98 lubricated o ring part 99 and brake piston part 92 into the brake cover part 90 WARNING Secure disc springs o ring and brake piston with brake release bolt See page 2 Dismantling the brake 4 Position the assembled brake cover part 90 line up the brake cover fastening bolt holes with the tapped holes in the hub cover part 80 Ensure that all gaps have been eliminated Remove the brake release bolt Measure the pre tightening value of the brake disc spring The clearance between the hub cover and brake cover is contained in the table Table 11 Brake housing pre tightening values mm 0 3 Basela elas oe aaa Go s Santasalo Hydraulics Oy Service manual to BBC serie Where the pre tightening value is lower than the value shown in the table place the reguired number of adjusting shims part 110 between the hub cover and the first brake disc in order to achieve the appropriate pretightening 5 Release the brake Insert the brake release bolt with nut into the hole in the center of the brake housing Screw the bolt with nut into the bottom of tapped hole located on the brake piston Tighten the release nut one full turn in order to release the brake 6 Insert and tighten brake housing fastening bolts part 111 Remove the brake release bolt and instal the tapered plug
8. d parts optional Insert the spring part 5 onto the 2 speed spool Insert another spring part 21 into the hole at the end of the 2 speed spool and place the oiled 2 speed spool into the shaft hole Place the assembled damper piston part 19 and orifice part 7 into the 2 speed spool hole Screw tightly the 2 speed spool plug part 6 with 8 mm allen key Use Loctite 243 sealant to sealing Place the sealing rings part 35 onto the shaft NOTE Clean the check valves part 11 and threads in the shaft very carefully Apply the Loctite 275 on the thread Screw the check valves part 11 into the shaft using 7 mm allen key The tightening torque of the check valve is 15 Nm 11 1 Ibf ft Santasalo Hydraulics Oy Service manual to BBC serie Ensure the mechanical lock of the check valve using the special tool CN9246 and a hammer Screw the plug part 14 with 8 mm allen key into the shaft and seal the threads with Loctite 275 Place the case pressure valve part 18 spring part 17 and plug part 16 into the hole at end of the shaft Screw the plug part 15 onto the shaft using an allen key NOTE The case pressure valve is marked 1 18 Place the filling valve part 160 Ei 16 spring part 161 and plug part 163 Daa into the hole at the end of the shaft S Screw the plug part 162 into the 460 15 shaft xn 163 Da NOTE The filling valve i
9. e 1 Spacer plate allen key sizes mm 95 9 Remove the sealing ring part 107 from the shaft groove 10 Remove the brake cover o ring part 100 from the hub cover 3 Hub cover and bearing detachment 1 Place a small screwdriver between the retainer rings part 82 and turn the clamp ring with the screwdriver part 85 as far as possible Pry the retainer ring part 83 out using a large screwdriver Santasalo Hydraulics Oy n Service manual to BBC serie Dismantling without hydraulic compression 3 Place the press tool against the hub bearing Screw M10 12 9 bolt through press tools hole Pre tighten the bearing but avoid overtightening Max tightening torque is 77 Nm Table 2 Press tool numbers Remove the retainer ring halves part 82 through the press tool holes Remove the press tool and detach the shims part 84 not in all models Dismantling with hydraulic compression 2 Place the press tool against the hub bearing Table 3 Press tool numbers Apply force to the bearing at 3 4 tons 6600 8800 lbs Remove the retainer ring halves part 82 through the tool holes Remove the press tool and detach the shims part 84 not in all models 3 Unscrew and remove bolts part 71 from the motor cover 4 Screw 3 housing bolts part 71 into the threaded extraction holes in the hub cover Detach the
10. oils and SC SD SE and SF motor oils In certain circumstances the use of non flammable fluids such as HFB and HFC may be permitted If using other fluids please contact Santasalo Hydraulics or our represantative Santasalo Hydraulics Oy 24 Service manual to BBC serie BLACK BRUIN 16 Spare parts When ordering spare parts please provide the following information part name part number quantity motor serial number Serial No motor part number Part No Santasala Hydraulics Oy N Fm4Y Made in Finland s ergs D santasalo Santasalo Hydraulics Oy PO Box 633 Fin 40101 Jyvaskyla Finland Tel 358 2048 4130 fax 358 2048 4131 email info hydraulics santasalo com http www santasalohydraulics com
11. ove and tap into place 16 Using the tool table 10 place the retainer ring part 85 and the locking ring part 83 on top of the retainer ring halves Table 10 Retainer ring installation tool number NOTE Ensure that retainer ring is locked S into its groove nd 83 17 Position the sealing ring part 107 onto W the shaft groove JAZ 85 18 Position the o ring part 101 onto hub cover groove 19 Lubricate the spacer plate sealing surface Place the spacer plate part 93 onto the hub housing Be careful not to snap the sealing ring Fasten the spacer plate using screws part 108 or retainer ring Apply Loctite 222 to secure the screws Santasalo Hydraulics Oy Loi EJ m 7 13 Brake reassembly Service manual to BBC serie 95 91 95 110 1 Position the inner retainer ring part 95 onto the shaft part 95 is not in all models Position the brake spline part 91 onto the shaft spline and lock by placing the outer retainer ring part 95 into the shaft groove 2 Place the brake discs parts 97 and 96 onto the brake spline First install the brake disc with friction surface usually friction surfaced brake discs gear teeth appear on the outside Position the discs in such a way that the discs have gear teeth alternately on the outerside and inside respectively Line up the discs 3 Position the dis
12. part 109 in the centre of the brake cover 14 After assembly Before using the motor Turn the motor to such a position that one of the bleed screws is in the topmost position Unfasten the bleed screw half a turn Fill the motor housing with oil Retighten the bleed screw when oil is pouring out from the outer end of the screw NOTE Unfilled motor casing will cause major motor damage aie N Test run the motor where possible NOTE When test running a multiple disc brake motor wheel fastening screws must be in place and tightly secured Santasalo Hydraulics Oy 23 Service manual to BBC serie BLACK 2 OHUIN MAINTENANCE 15 Recommended oil Any mineral oil to be used should meet the following reguirements The viscosity index must be no less than 100 If the oil contains additives to improve viscosity index their effect must be as long lasting as possible Oil should retain its reguired viscosity throughout its life The lowest accetable viscosity is 15 cSt Recommended viscosity area at operating temperature is 25 40 cSt At reduced speed to achieve smoother running a more viscous oil can be employed Oil temperatures of over 70 C 160 F should be avoided as the useful life of the oil and of the entire system is drastically reduced from the effects of temperatures above this Oil additives must comply with the API classification of SC motor oils We recommend hydraulic
13. part 69 69 support ring part 68 o ring part 72 not in all models and shaft seal part 67 from the rear cover 3 Lift the inner bearing race part 66 from A 6 the rear cover Only detach the outer bearing w race from the rear cover if the bearing is being replaced 4 By hand screw three cover bolts into the threaded extraction holes on the rear cover Detach the cam ring part 115 by evenly tightening the bolts Tap the expander pin part 73 loose from the cam ring Remove the o ring part 116 from the rear cover groove Santasalo Hydraulics Oy a Service manual to BBC serie 6 Dismantling the shaft 1 If needed heat up the shaft seal collar part 2 to a temperarure of about 80 C 1 76 F Pry the collar part 2 from the shaft Remove the o ring part 3 from the shaft groove 2 Dismantling 2 speed parts optional Only if check valve malfunction is observed Remove the plugs part 14 with 8 mm allen key and check valves part 11 with 7 mm allen key Inspect the functionality and cleanliness of the check valve Unscrew the plug part 6 with 8 mm allen key from the shaft with an allen key It may be necessary to heat the plug to ease unscrewing Remove the orifice part 7 damper piston part 19 and spring part 21 Dismantle the damper piston if damage or dirt is observed parts 19 20 and 22 Remove spool part 4 and spring part 5 from shaft hole Parts 19 and
14. roperly tightened the two brake cover fixing screws will not withstand the braking torque during testing Empty any oil from the motor housing by unscrewing the bleed screws part 74 2 Dismantling the brake Place the motor on the work bench with the brake cover pointing upwards 1 Loosen the tapered plug in the centre of the brake cover using an allen wrench 2 Insert the brake release bolt with nut into the hole in the center of the brake housing Screw the bolt with nut into the bottom of tapped hole located on the brake piston Tighten the release nut one full turn in order to release the brake Santasalo Hydraulics Oy 3 Service manual to BBC serie 3 Remove the brake cover lock screws part 111 using allen key Carefully lift the brake cover straight upwards 4 If the brake piston o ring part 99 is leaking loosen the brake release bolt from 99 the brake cover and release the brake piston part 92 from the brake cover using a drift and a hammer Replace the brake piston o ring part 99 5 Remove brake discs parts 96 and 97 6 Remove the retainer ring part 95 from its groove and take out the splined hub part 91 n 100 101 7 Remove the inner retainer ring part 95 from its groove not in all models 8 Loosen the spacer plate part 93 lock 80 screws part 108 from the hub cover part 80 Remove the spacer plate and its o ring part 101 4 108 Tabl
15. s marked 2 a NA NOTE If the shaft is new tap the valves carefully in place and ensure the tightness of the sealing surface The sealing surface should display an intact grey circle following the tap Santasalo Hydraulics Oy Service manual to BBC serie 8 Cylinder block 29 1 Poppet valve installation a optional 2 speed motor CD PA J 28 Insert the valves part 36 to same cylinder block holes as they were Insert springs part 33 and screw the cylinder block plugs part 34 using an allen key The tightening torque is 50 2 Nm Table 5 Cylinder block plug allen key Sizes 2 Insert the piston rings part 28 if they have been removed Insert the oiled cam rollers part 29 into pistons Place the oiled pistons part 26 into cylinder block 3 Place the guide rings part 30 into cylinder block grooves Tap the expander pins part 31 into their holes NOTE The shamfered sides of the guide rings should face away from the pistons with the flat side facing the piston rollers 4 Freewheeling mechanism installation optional Assemble the freewheeling mechanism only if it has been dismantled Santasalo Hydraulics Oy n Service manual to BBC serie Insert the spring heads of the assembled freewheeling mechanism into the cylinder assembly grooves Place the U plates part 42 and spacer sleeves part 41 in place against the spring Insert screws
16. the distribution valve part 50 into place 6 Rotate the distribution valve at the same time as pressing it lightly and evenly by hand When the distribution valve pins line up with the connecting ring grooves apply a little more force to the distribution valve Where necessary tap the distribution valve lightly with a soft device Do not tap the distribution surface Santasalo Hydraulics Oy 47 Service manual to BBC serie 7 Clean the distribution surface in the distribution valve and in the cylinder block and oil them Fit the assembled cylinder block onto the shaft splines 8 Press the cylinder block and place the retainer ring halves part 37 onto the shaft groove Position the locking ring part 44 over the retainer ring halves 9 Place the hub cover into place ensure Q that none of the hub housing threaded O extraction holes line up with the expander pin and that the o ring part 116 is in its 3 44 groove 10 Tighten the hub cover into place evenly using cover bolts Tighten all cover bolts around the circumference of the hub cover Table 6 Tightening torque of the cover bolts and allen key sizes 135Nm 135Nm 135Nm 135Nm_ 10mm 10mm 10mm 10mm o Bearing installation using hydraulic compression 11 Place both retainer ring halves onto the shaft groove only in models with shims Position the bearing press tool over the hub bearing Remove all gaps between the h
17. the spacer sleeves part 41 U plates part 42 and the freewheeling mechanism from the cylinder block Do not dismantle the freewheeling mechanism unless damage or excessive wear is observed 7 Tap loose the piston guide expander pins part 31 Remove the piston guide rings part 30 from the grooves on the cylinder block 8 Pull out the pistons part 26 from the cylinder block and remove the cam rollers part 29 from the pistons 9 Check the condition of the pistons piston inserts cam rollers cam ring and the cylinder block Replace if any damage is observed 10 Dismantling poppet spool optional only in 2 speed motors Open plugs part 34 in cylinder block using an allen key 26 Table 4 Allen key sizes 34 33 Remove springs part 33 from the poppet spool holes Santasalo Hydraulics Oy 7 Service manual to BBC serie Remove poppet spools part 36 from the cylinder assembly Check the sealing surface condition of poppet spools Replace the poppet spools if any damage is observed Do not mix up the order of the spools 33 5 Dismantling rear cover 1 Remove the sealing rings parts 51 52 and 53 from the shaft grooves Lift the rear cover part 65 completely off the shaft NOTE Do not dismantle the rotation unit A for distribution valve part 55 unless it shows signs of damage or the deflection is uneven 2 Remove the retainer ring
18. ub cover and the bearing by applying a force See table 7 pretightening to the bearing and rotate the cover a few turns by hand Release the pressure and retighten applying the force See table 7 measuring Santasalo Hydraulics Oy hal Service manual to BBC serie Table 7 Bearing pressure force kN 11a Models with shims Measure and record the gap C1 between the bearing and the retainer ring halves 11b Models without shims Measure and record the gap C1 between the bearing and the upper edge of the retainer ring groove Bearing installation without hydraulic compression 12 Place the press tool with a bolt M10 12 9 in the centre onto the hub bearing Remove the gap between the hub cover and the bearing by tightening the press tool tension screw See table 9 pretightening and rotate the cover a few turns by hand Loosen the tension screw and retighten See table 9 measuring 12a Models with shims Measure and record the gap C1 between the bearing and the retainer ring halves 12b Models without shims Measure and record the gap C1 between the bearing and the upper edge of the retainer ring groove You can use thin retaining ring halves to ease measuring Table 8 Hub cover bearing tool numbers Santasalo Hydraulics Oy Models with shims C1 Models without shims Press tool Table 9

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