Ideas taking shape - worldwide.

Dokumentnr. 049200304-en HÜBNER GmbH · Werk Waldau

Document No. Heinrich-Hertz-Straße 2 · D-34123 Kassel
Erstell Datum: 2010-06-23 Postfach 10 19 20 · D-34019 Kassel
Date Tel. +49 (0)561 998-0 Fax +49 (0)561 998-1543
Änderungsstand E
Revision
English Translation

Replacing components
Damping cylinder with / without emergency damping

Proportional valve (yellow)

Pressure sensor (blue)

Pressure sensor (green)

Proportional valve (red)

Emergency damping valve (white)

© HUEBNER GmbH
The reproduction, distribution and utilization of this document as well Ersteller Ritter/Heupke
Author
as the communication of its contents to others without express Geprüft
Karasek
authorization is prohibited. Offenders will be held liable for the payment Checked
of damages. All rights reserved in the event of the grant of a patent, Freigegeben
Approved
Karasek
utility model or design. In case of doubt the German document shall
take precedence over a translation.

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Contents
1.  Safety instructions ............................................................................................................... 3 
2.  Replacing the damping cylinder ......................................................................................... 4 
2.1  Arrangement of cables and fixation to the damping cylinders ............................................... 7 
3.  Replacing the pressure sensor ........................................................................................... 8 
4.  Replacing the magnetic coil (emergency damping valve) ............................................. 10 
5.  Replacing the spherical bearing ....................................................................................... 11 

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 Ideas taking shape - worldwide.

1. Safety instructions
 We hereby explicitly state that all mounting, maintenance and servicing works must be
carried out properly and professionally to ensure the vehicle's safety and passengers'
safety!

 Warranty claims according to our sales condition can only be accepted if one will be able
to proof (by means of an execution proof of the workshop) that all maintenance works
have been carried out on schedule by qualified personnel!

 Only repair works described in this document (049200304_F_en.docx) are allowed to be

carried out at the damping cylinders!

 Further repairs must be carried out by HUEBNER Service only!

Important information: This mark indicates an important assembly step which should be carried out!

Warning! This mark indicates information of potential danger. Failure to observe this warning may
! result in injury or damage to the component!

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2. Replacing the damping cylinder

 Remove the articulation platform.
 Disconnect the electrical plug at the damper, release and remove cable and holder from the damper.

Make sure that all connecting cables, plugs and receptacles are marked according to
color codes - this will simplify subsequent mounting!

Step 1: remove M10 hex socket cap bolts Step 2: remove bearing bolts of the
and retaining washer of the bearing bolts. damping cylinder vertically by means of a
stud bolt M20 and a jig.

Step 3: remove the old damping cylinder. Step 4: replace supporting disk. Place new
supporting disk exactly around the bore of the
Protect damping cylinder from damper receiver.
falling down! Place the new sealing on the new damping
! The damping cylinder weighs
40 kg!
cylinder. Pay attention to the marking "TOP" at
the damping cylinder (top side).
Check the correct seating of the sealing!
The sealing must fit on the sliding ring
and the sealing lip must rest
completely on the new damping
cylinder!

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Step 5: for easier mounting use a liquid lubricant

that is almost ph-neutral (e.g. soapy water 0.1%)
and apply a very thin layer on one side of the
metal sheet. This will protect the sealing and will
also allow easy removal of the metal sheet.
Step 6: place metal sheet on the sealing, make
sure the side with soapy water is facing down.
Push the new damping cylinder in the damping
receiver.
Step 7: carefully remove the metal sheet.

Check the correct seating of the

sealing!

Step 8: use a soft faced mallet to drive in Step 9: insert M10 hex socket cap bolts and
the bearing bolt. retaining washers and tighten with torque wrench.

Tightening torque:
M10 hex socket cap bolt =50 Nm

Step 10: replace support ring. Step 11: place the new sealing on the new
Place new support ring exactly around damping cylinder and check the correct seating
the bore of the damping receiver. of the sealing!

The elastic side of the support ring must The sealing must fit on the sliding ring and the
be facing down. sealing lip must rest completely on the damping
cylinder!

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Step 12: for easier mounting use a liquid

lubricant that is almost ph-neutral (e.g. soapy
water 0.1%) and apply a very thin layer on one
side of the metal sheet.
This will protect the sealing and will also allow
easy removal of the metal sheet.
Step 13: place metal sheet on the sealing, make
sure the side with soapy water is facing down.
Push the damping cylinder back in the damping
receiver.
Step 14: carefully remove the metal sheet.

Check the correct seating of the

sealing!

Step 15: use a soft faced mallet to drive in Step 16: insert M10 hex socket cap bolts and
the bearing bolt. retaining washers and tighten with torque wrench.

Check the correct seating of the sealing!

Adjusting the length of the new dampers:

 Move damper without emergency damping (2 plug-in connections) at piston rod.
 In order to move of the piston rod use e.g. a tensioning belt.
 Damper with emergency damping (3 plug-in connections) should be additionally supplied with 24 V
at the emergency damping valve (white color code) in order to move the piston rod.

After mounting the radial bearing seals:

 Connect the electrical plug to the damping cylinder, attach cables and holder to the damping cylinder.

Make sure that all cables, plugs and receptacles are connected according to color
codes!

 Mount the articulation platform

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2.1 Arrangement of cables and fixation to the damping cylinders

When the articulation system bends, the cable joints to the plugs of the damping cylinders are
exposed to motion. In order to attain the most suitable arrangement of the cables in this area, a color
marking is made on the corrugated tubes in defined positions by means of insulation tape. The five
corrugated tubes are marked as follows:
Direction of travel: right (damping cylinder 1):
 Proportional valve: red
 Pressure sensor: green
 Emergency damping valve: white
Direction of travel: left (damping cylinder 2):
 Proportional valve: yellow
 Pressure sensor: blue

The same color markings are provided at the plugs of the damping cylinders!

The arrangement starts at the cylinder base. The first marking has to be at the opening of the cylinder
base right before the cable binder at the cable retainer (see picture 1 and 4). The second marking has
to be at the larger opening of the cable retainer below the damping cylinder (see picture 2 and 5).
Fix the corrugated tubes with cables binders to the cable retainers of the cylinder base right/left as
shown in pictures 1 and 4 as well as to the tube of the damping cylinder (picture 3 and 5).
Please observe that the bending radii are arranged as shown in the pictures and the corrugated tubes
are laid in parallel. Fix the cable retainer below each damping cylinder and fasten with 3 cable binders
(picture 2 and 5).

During motion testing the corrugated tubes should not wear or bend in any place!
! There should also be no tensile loading in the maximum bending angles!

1 2

Picture 1

Picture 2

Picture 3 Picture 4 Picture 5

Figure 1: Arrangement of cables and fixation to the damping cylinders

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3. Replacing the pressure sensor

The pressure sensor provided at the right damping cylinder (in direction of travel) can be replaced in
installed condition of the damping cylinder.
When replacing the pressure sensor provided at the left damping cylinder (in direction of travel) the
damper should be removed. Mounting works should be carried out on a work bench
(removal of the damping cylinder see page 4).

Store damping cylinder only horizontally to minimize hydraulic fluid loss!

 Remove connector from pressure sensor (Figure 2/B).

 Carefully open filler plug (Figure 2/A) (loosen rather than remove plug) to adjust reservoir to the
ambient pressure.
 Close filler plug (Figure 2/A) and tighten using 20 + 5 Nm torque.
 Place oil collecting pan below damping cylinder to collect any escaping oil.
 Prepare new pressure sensor.
 Renew seal ring (Figure 2/C)
 Apply retaining compound (Loctite 243) to screw thread in accordance to manufacturer’s instructions.
 Unscrew pressure sensor.

Remove loose screw retaining compound residues and old seal ring from the valve
bock using a lint-free, clean cloth!

Work quickly to minimize hydraulic fluid loss!

 Install and torque tighten new pressure sensor

 Please observe the following:
 Install pressure sensor hand-tight.
 Continue to screw in pressure sensor by a minimum of 180° using a wrench.
 If the connector position is not correct, the sensor may be screwed in another 180°
maximum.

The pressure sensor must not be unscrewed again!

! If it is unscrewed, the sealing must be replaced!

When tightening make sure not to exceed 28 Nm torque!

!
 Reinstall connector on pressure sensor observing color code identification.
 Check damping cylinder for correct operation using the diagnostics software (see HÜBNER service
instructions ACU P/N 0492 00173 00-002).
 Test drive vehicles without ACU
 Complete a functional test of the hydraulics of the articulation system.

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Damping cylinder right

Damping cylinder left

A
A

C
Wrench size 30
Pressure sensor

Figure 2: Replacing the pressure sensor

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Ideas taking shape - worldwide.

4. Replacing the magnetic coil (emergency damping valve)

 Remove connector from magnetic coil (Figure 3/A).
 Loosen nut with wrench size 19 (Figure 3/B) and remove solenoid coil from 3/2 way valve.

Take care of solenoid seal rings!

!
 Mounting the new magnetic coil.

Tightening torque: nut with wrench size 19 = 3,4+0,5 Nm

 Reinstall connector on magnetic coil observing color code identification.

 Check damping cylinder for correct operation using the diagnostics software (see HÜBNER service
instructions ACU P/N 0492 00173 00-002).
 Test drive vehicles without ACU and complete a functional test of the hydraulics of the articulation.

Magnetic coil

Seal ring

Figure 3: Replacing the magnetic coil (emergency damping valve)

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5. Replacing the spherical bearing

 Remove the damping cylinder (see page 4).

 Remove the retaining rings (Figure 4/A).

 Remove spherical bearing P/N 0448 23018 00 (Figure 4/B) from rod end or tailpiece, as applicable,
using a suitable tool (hydraulic press with special removal sleeves outside-diameter 67 mm inside
diameter 60 mm).

 Check bearing seat for scores (induced by bearing removal). Scores as deep as 0.1 mm may be
removed by polishing with fine abrasive paper. If scores are deeper the complete damping cylinder
must be replaced!

Polish scored areas only! After reworking the bearing area shall still ensure a
! firm seating of the spherical bearing (press fit)!

 Install new spherical bearing in rod end or tailpiece, as applicable, using a suitable device (hydraulic
press with special installation sleeves).

! The area where the outer ring is split must be at 90° to the main load direction!

 Reinstall the retaining rings (Figure 4/A).

A B

A
Figure 4: Replacing the spherical bearing

The articulation bearings at the damper are maintenance-free and must not be
! lubricated!

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