An hour from now you could have the front cover off a leaking wheel motor with this 72-page Poclain Hydraulics MK04, MKD04 repair manual PDF, factory document 800078102T covering both hydraulic motor variants. Troubleshooting trees walk from five symptoms (noisy motor, no rotation, low speed under load, rough running, external leaks) straight to the seal or valve at fault. Full teardown and rebuild sequences cover the brake piston seals, the distribution face and seals, the lip seal and protection plate, and a complete rotor plus stator inspection with wear assessment, backed by standard and special tooling lists. Before you refit the brake, confirm release pressure sits between 17 and 30 bar (246.6 to 435.1 PSI), then pull every fastener value from the torque summary table. Guess a brake pressure wrong and a loaded machine can roll. Bookmarked and text searchable, this PDF rides on whatever screen you carry out to the motor. Poclain published this one bilingually: the troubleshooting charts run French then English on facing pages, and the repair chapters carry both languages side by side, so every procedure, caption and torque figure is there in English.
What's Inside This Repair Manual
| System | Pages | Key Topics |
|---|
| Trouble Shooting | 4-11 | The Motor Is Noisy, The Motor Does Not Revolve, The Motor Does Not Revolve at Its Normal Speed Under Load, The Motor Revolves Irregularly, The Motor Leaks |
| Basic Operations | 12-17 | Prerequisite (Related Documents, Component Identification), Safety and Quality (Before Servicing, During Servicing, After Servicing) |
| Mechanical Brake Release System (006) Replacement | 18-20 | Removing Plugs (191), Notched Rings (195), Screws (192) and Springs (193) From the Valving Cover, Refitting the Spacer Guides (196), Torquing the Plugs to Spec |
| Protective Plate (171), Lip Seal (172) and Sealing Ring (027) Replacement | 21-25 | Extracting the Lip Seal and Snap Ring (028), Checking the Seal Housings on Rotor (011) and Stator (026), Lubricating and Seating the New Sealing Ring, Refitting Thrust Washer (034) and Protective Plate |
| Sealing Unit (115)+(118)+(028) Replacement on the Hollow Shaft Motors | 26-30 | Removing Snap Rings (109) and (116), Extracting Tube (110), Replacing O-Ring (115), Sealing Ring (118) and Bushing (128), Checking the Mating Surfaces Before Reassembly |
| Brake Piston (107) Sealing (106)+(111) Replacement | 31-41 | Pressing the Valving Cover Off at 8800 N, Releasing the Mounting Screws in Diagonal Quarter Turns, Extracting the Brake Piston, Replacing O-Ring (106) and Sinus O-Ring (111), Brake Seal Pressure Test at 17 to 30 Bar |
| Valving (047) or Valving Seals (048) Replacement | 42-46 | Extracting the Timing Pin (050) and Springs (051), Replacing Back-Up Rings (048-1) and O-Rings (048-2), Heating the Back-Up Rings Before Fitting, Refitting the Valving Into the Cover |
| Rotor (011) and Stator (026) Assembly Inspection | 47-56 | Extracting the Balls (035) and Bearing Cage (036), Removing the Piston Assemblies (012), Visual and Nail Check of Piston Lapped Surfaces and Rollers, Rotor Bores, Stator Rolling and Bearing Track Surfaces, Brake Sealing Surfaces |
| Plug (114) Replacement | 57 | Stripping Down per the Brake Piston Sealing Chapter, Driving the Plug Out with a Bronze Casting Without Damaging the Rotor (011) Splines, Fitting the New Plug |
| Tooling Inventory | 58-62 | Commercial Tools, Specific Tools |
| Tightening Torques | 63 | Tightening Torques Summary, Standard Tightening Torques by Screw Class 8.8, And 12.9 |
| Spare Parts | 64-72 | Generic List of Item Numbers and Designations, Seal Kits (003, 006, 007, 061) and the Assemblies They Belong to |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| All Models |
| Brake release pressure | 17 to 30 bar [246.6 to 435.1 PSI] | p. 38 |
| Back-up ring (048-1) heating | 125°C [257°F] for 15 min in a furnace, or oil at 100°C [212°F] for 5 min | p. 44 |
| motors with the 10 bar brake release option |
| Brake release pressure, low-pressure release option | 10 bar | p. 34 |
| motors fitted with a snap ring |
| Valving cover (041) assembly press force | 8800 N [1978 lbf] | p. 39 |
| MK04, MKD04 |
| Brake mechanical release plug (191) torque, M16 | 60 ±6 N.m [44 ±4.4 lbf.ft] | p. 63 |
| Brake mechanical release CHC screw (192) torque, M8 | 30 ±3 N.m [22 ±2.2 lbf.ft] | p. 63 |
| Valving cover CHC screw (042) torque, M8 | 41 ±4 N.m [30 ±3 lbf.ft] | p. 63 |
