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5018 PDS 2003
Repair Manual
99 pgs5.16 Mb2

WP Suspension 5018 PDS 2003 Repair Manual

4.3 (4)
Workshop manual
5018 PDS 2003
Product
Exploded View Disassembly & Assembling
Shock absorber 5018 PDS 2003 05/2002
Shock absorber
Introduction 2 Exploded view 3 Disassembly shock absorber 4 Disassembly tube side 13 Disassembly MCC 33 Assembling MCC 39 Assembling Tube side 44 Disassembly piston-rod side 53 Diassembly adaptor DU-bush 63 Assembling adaptor DU-bush 67 Assembling piston-rod side 70 Assembling shock absorber 81 Bleeding 87 On pressure with nitrogen 92 Mounting spring 95 Adjustment 98
1
Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
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.
Introduction
Always use aluminium protector-plates, when clamping our products or parts in the vice.
Always replace damaged or worn parts.
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!!
Shock absorber 5018 PDS 2003 05/2002
Werkplaatshandboek
2
Workshop manual
5018 PDS 2003
Product
Exploded View
Disassembly & Assembling
Exploded view
Shock absorber 5018 PDS 2003 05/2002
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.
Werkplaatshandboek
MCC
MCC = Mono Compression Control
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. Fully closed is turning the adjustment screw clockwise.
Shock absorber 5018 PDS 2003 05/2002
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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.
Werkplaatshandboek
Measure the length of the spring. Spring preload.
Unscrew the Allen bolt (size 4).
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Release the spring preload with open spanner T106.
Werkplaatshandboek
Screw the screw retainer against the lock retainer.
Disassemble the spring retainer and springring.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Remove the washer.
Werkplaatshandboek
Remove the spring. Pay attention to the assembling direction!!!
Remove the second washer.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Spring with washers, spring retainer and springring.
Shock absorber 5018 PDS 2003 05/2002
Werkplaatshandboek
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Disassemble the rubber cap.
Werkplaatshandboek
Unscrew slowly the nitrogen plug (size 4) to release the pressure.
Nitrogen plug with O-ring.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Tap the cap from the tube.
Werkplaatshandboek
1. Place disassembling bush T1216 on the adaptor DU-bush.
2.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Push the adaptor DU-bush downwards.
Werkplaatshandboek
Disassemble the springring out of the tube.
Springring.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Pull carefully but firmly the piston-rod “complete” out of the tube.
Shock absorber 5018 PDS 2003 05/2002
Push with depth-stop T107S the separation piston downwards.
Werkplaatshandboek
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Disassembly tube-side
Drain the oil out the tube.
Werkplaatshandboek
Clamp the tube side in the vice.
Remove the springring out of the groove and slide it a little bit downwards.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Slide the guiding bush downwards.
Werkplaatshandboek
Remove the upper springring.
Remove the guiding bush. Pay attention to the assembling direction!!!
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Remove the springring.
Werkplaatshandboek
Spring guiding bush with the two springrings.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Turn the screw-retainer of the tube.
Werkplaatshandboek
Screw-retainer with the Allen bolt.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Unscrew the screw-cap of the MCC (size 24) (DCC also size 24)
Werkplaatshandboek
Remove the screw-cap.
Remove the washer inside the screw­cap, or on top of the spring inside the bottom.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Remove the spring.
Werkplaatshandboek
Pull the damping holder “cpl” out of the bottom.
Srew-cap with adjustment needle, spring and the MCC damping holder “cpl”.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Heat the lock retainer.
Werkplaatshandboek
Unscrew the lock retainer with open spanner T1233.
Screw the lock retainer of the bottom.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Heat the bottom near the tube.
Werkplaatshandboek
Use slide-spanner T146 with bush T1201.
Unscrew the tube.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Screw the tube out of the bottom.
Werkplaatshandboek
Screw the lock retainer of the tube.
Tube with lock retainer.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Disassemble the O-ring out of the groove inside the bottom.
Werkplaatshandboek
Place dis- / assembling tool T145S on top of the screw-cap
Place pin spanner T125S onto T145S.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Heat the reservoir near the bottom.
Werkplaatshandboek
Unscrew the screw-cap.
Turn the reservoir from the bottom.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Remove the O-ring.
Werkplaatshandboek
Bottom “cpl” with both O-rings.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Pay attention to the assembling direction!!!
Push the separation piston out of the reservoir.
Werkplaatshandboek
Separation piston.
Disassemble the O-ring.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Separation piston, piston ring and O-ring.
Shock absorber 5018 PDS 2003 05/2002
Werkplaatshandboek
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Clamp the bottom in the vice.
Werkplaatshandboek
Use disassembling tool T120 for disassembling the adaptor bushes.
Tap the adaptor bush out of the heim­joint.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Remove the seal.
Werkplaatshandboek
Disassemble the springring.
Tap the other adaptor bush out of the heim-joint.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Use Dis- / assembling tool T1207S for disassembling the heim-joint.
Werkplaatshandboek
Press the heim-joint out of the bottom at the side were the springring is removed.
Adaptor bushes, seals, springrings and heim-joint.
Shock absorber 5018 PDS 2003 05/2002
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Workshop manual
5018 PDS 2003
Product Exploded View
Disassembly & Assembling
Replace one springring.
Werkplaatshandboek
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.
Shock absorber 5018 PDS 2003 05/2002
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