Denison Hydraulics Premier Series Operating and installation instructions

DENISON HYDRAULICS
open loop pump controls
series P140 A-mod, P260 B-mod
service information
Publ. S1-AM024-A replaces S1-AM024 01-97
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CONTENTS
typical characteristics-------------------------------------------------------------------------------
fluid connections-------------------------------------------------------------------------------------
introduction------------------------------------------------------------------------------------------
general---------------------------------------------------------------------------------------------
description-----------------------------------------------------------------------------------------
pressure compensator----------------------------------------------------------------------------
remote compensator control---------------------------------------------------------------------
load sensing control------------------------------------------------------------------------------
torque limiter--------------------------------------------------------------------------------------
rotary servo control-------------------------------------------------------------------------------
hydraulic stroker----------------------------------------------------------------------------------
electric stroker-------------------------------------------------------------------------------------
pressure compensator override and torque limiter override--------------------------------
troubleshooting chart-------------------------------------------------------------------------------
pressure compensator parts list-------------------------------------------------------------------
figure 1 & parts list, maximum volume stop---------------------------------------------------
figure 2 & parts list, maximum volume handwheel------------------------------------------
compensator disassembly, assembly, test-----------------------------------------------------
figure 3 & parts list, compensator cap---------------------------------------------------------
buck-up cap disassembly, assembly------------------------------------------------------------
figure 4 & parts list,buck-up cap----------------------------------------------------------------
electric stroker parts list----------------------------------------------------------------------------
electric stroker disassembly, assembly, test---------------------------------------------------
figure 5, electric stroker--------------------------------------------------------------------------
figure 6, servo cap---------------------------------------------------------------------------------
parts lists for figure 5 and figure 6-------------------------------------------------------------
control cap disassembly, assembly-------------------------------------------------------------
figure 7 & parts list, control cap----------------------------------------------------------------
torque limiter override disassembly & assembly---------------------------------------------
figure 8 & parts list, torque limiter override--------------------------------------------------
figure 9 & parts list, torque limiter override cap---------------------------------------------
torque limiter override test and adjustment---------------------------------------------------
compensator override disassembly, assembly, test-------------------------------------------
figure 10 & parts list, compensator override--------------------------------------------------
hydraulic stroker parts list-------------------------------------------------------------------------
hydraulic stroker disassembly, assembly, test-------------------------------------------------
figure 11 & parts list, hydraulic stroker--------------------------------------------------------
torque limiter parts list-----------------------------------------------------------------------------
torque limiter disassembly & assembly--------------------------------------------------------
figure 12, torque limiter--------------------------------------------------------------------------
figure 13, torque limiter cap---------------------------------------------------------------------
parts lists for figure 12 and figure 13----------------------------------------------------------
torque limiter test and adjustment--------------------------------------------------------------
rotary servo parts list-------------------------------------------------------------------------------
rotary servo disassembly, assembly, test-------------------------------------------------------
figure 14 & parts list, rotary servo-------------------------------------------------------------
load sensing control parts list---------------------------------------------------------------------
load sensing control disassembly, assembly, test---------------------------------------------
figure 15 & parts list, load sensing control---------------------------------------------------
hydraulic circuits------------------------------------------------------------------------------------
pressure compensator----------------------------------------------------------------------------
pressure compensator with load sensing configuration--------------------------------------
torque limiter--------------------------------------------------------------------------------------
manual rotary servo------------------------------------------------------------------------------
manual rotary servo with compensator override---------------------------------------------
manual rotary servo with torque limiter override--------------------------------------------
electric stroker-------------------------------------------------------------------------------------
electric stroker with compensator override----------------------------------------------------
electric stroker with torque limiter override---------------------------------------------------
hydraulic stroker----------------------------------------------------------------------------------
hydraulic stroker with compensator override-------------------------------------------------
hydraulic stroker with torque limiter override------------------------------------------------
load sensing control------------------------------------------------------------------------------
stroker performance--------------------------------------------------------------------------------
installation drawings--------------------------------------------------------------------------------
controls key sheet------------------------------------------------------------------------------------
technical data conversions-------------------------------------------------------------------------
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3
Specification
• compensator response off-stroke
on-stroke
• compensator adjustment
• minimum compensating pressure (comp, torque limiter)
• minimum compensator override pressure (servo, electric
& hyd. str.)
• torque limiter adjustment range code J
code K
• typ. servo & stroker response @ 83 bar servo pressure,
zero to full stroke and vice versa
• servo flow required for this response (E, H, R10 controls)
• servo flow required for this response (*1J, *1K, *1P
controls)
• maximum servo pressure
• servo shaft rotation, 0 to full volume
• displacement/rev./degree servo shaft rotation
• hydraulic stroker control pressure 0 displacement
full displacement
• electric stroker control amps (24v.) 0 displacement
full displacement
pulse width modulation frequency:
mating connector: Din 43650 type AF
part no. 167-10008-8 (provided)
• electric stroker nominal coil resistance (24v. coil)
• electric stroker nominal coil resistance (12v. coil)
• handwheel turns, full to zero stroke
• torque to turn handwheel @ 70 bar
• torque to turn handwheel @ 500 bar
• torque to turn rotary servo shaft
• port C1, C2 (cylinder gage ports)
• port E (electric stroker control pressure inlet)
• port H (hydraulic stroker control pressure inlet)
• port LS (load sensing port)
• port V (compensator vent)
• port X (rotary servo, electric & hydraulic stroker servo
inlet)
Term
sec.
sec.
bar/turn
bar
bar
Nm
Nm
sec.
l/min.
l/min
bar
degrees
cc/rev/deg.
bar
bar
mA
mA
Hz
ohms
ohms
turns
Nm
Nm
Nm
BSPP
BSPP
BSPP
BSPP
BSPP
BSPP
P260
0,100
0,150
138
17,2
93,1
282 - 706
706 - 1129
<0,6
11,4
15,2
103
80
3,25
3,45
19
150-200
390
100-150
41
10
10
17
40
2,3
1/4
1/4
1/4
1/4
3/8
3/8
TYPICAL CHARACTERISTICS
FLUID CONNECTIONS
CHARACTERISTICS
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The instructions contained in this manual cover complete disassembly and reassembly
of the controls. Before proceeding with the disassembly or reassembly of any unit, this
manual should be studied in order to become familiar with proper order and parts
nomenclature.
A piloted three-way valve spool and sleeve combination is the nucleus of the control
function. For the compensator, torque limiter and load sensing controls, system
pressure is applied to the input port of the valve, and to one end of the spool. A
small orifice feeds this pressure to the other end of the spool, and limits pilot flow
to approximately 1,9 l/m. A spring on this end biases the spool to normally port the
control cylinder to pump case.This control cylinder links to the pump cam. On the
opposite side of the control cyllinder, a pin connected to system pressure, pump
timing forces, and a spring combine to put the pump on stroke.
A spring-loaded cone and seat connected to the spring end of the three-way spool
establishes an adjustable pressure limit on this end of the spool. When system pres-
sure reaches this value, flow through the spool creates a pressure difference across
the spool. At approximately 17,2 bar difference, the spool shifts toward the spring, re-
directing the control cylinder port to pressure.This pressure applied to the control
cylinder overcomes the forces putting the pump on stroke, causing the pump to reduce
displacement.When the pump pressure drops, the spool shifts the other way to main-
tain the pump pressure at approximately 17,2 bar above the controlled pressure on the
spring side.The spring end of this three-way spool may also be connected to a remote
pressure control, through the vent port, V.
For load sensing, this “V” port is connected to the load. The pump compensator will
supply approximately 17,2 bar above the load pressure.The valve between the pump
and the load meters the flow.The pump provides the flow to develop 17,2 bar drop
across the valve independent of the load pressure and thus becomes a flow control
independent of operating pressure. Adjustment of spring load on the three-way spool
allows precise control of the differential pressure.
Where the approximately 1,9 l/m vent flow cannot be accommodated by the load
sensing circuit, and where multiple loads are to be controlled, a load sensing control
is available. In the load sensing control, the vent flow is modulated by a valve which
senses load pressure and establishes the pump compensator pressure at 21 bar
above load pressure.There is essentially no flow in the sensing line.
For torque limiting, system pressure and pump displacement are controlled by the for-
mula P•V=K. As pressure increases, displacement must reduce, and vice versa. A link-
age to the pump control cylinder slides a spool over a pin. The spool and pin act as a
metering valve.The pin contains a cross drilled hole, and a connecting drilling to one
end.This pin passes through a bore in the torque limiter housing connecting to the
vent port of the compensator. The pressure in the vent port applies a force on the pin,
which is resisted on the other end by a two spring combination.
The pin positions itself to where the vent pressure force on the one end is balanced by
the spring force on the other end.When the cross drilled hole opens, it causes the
three-way spool to shift to direct system pressure into the control cylinder, reducing
stroke. The linkage to the control cylinder causes the spool to move in the direction to
close the cross-drilled hole.Thus, for every position of the pin, there is a corresponding
position for the control cylinder. The position of the pin is determined by the pressure,
the spring rate, and the initial adjustment on the springs. As pressure increases, pump
stroke must reduce.
At low pressure, only the outer spring contacts the spool. As pressure increases, the
second spring also makes contact. Thus the rate of change of pressure starts at a low
initial rate when the pump is at full stroke and changes to a high rate at reduced
stroke, to approximate the P•V=K relationship. The normal compensator function is
retained to provide a maximum pressure limit.
The rotary servo control is mounted on the off-stroke side of the control cylinder. The
control piston has a large diameter on this side, and a smaller diameter on the oppo-
site side. Servo pressure is connected to the input port on the three-way valve, and
also to the smaller diameter side of the control piston.
When the three-way spool is at rest, the control piston is ported to tank, and servo
pressure applied to the opposite, smaller diameter piston causes the rocker cam to
stroke to minimum.When the three-way spool shifts, pressure is directed into the
larger diameter of the control cylinder causing the cam to shift towards full stroke.
The pin described above is spring loaded against a mechanism which converts rotary
motion of the input shaft to linear motion of the pin, thus positioning pump stroke pro-
portionately to input shaft rotation.
In the hydraulic stroker, a spring loaded piston is attached to the above pin. A control
pressure of 3,45 bar causes the piston to commence to move against the spring, to
position the pin in proportion to the control pressure, and thus cause the pump to
INTRODUCTION
GENERAL
DESCRIPTION OF OPERATION
PRESSURE COMPENSATOR
LOAD SENSING CONTROL
TORQUE LIMITER
ROTARY SERVO CONTROL
HYDRAULIC STROKER
4
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stroke in proportion to control pressure. Full stroke is achieved at 19 bar.
By mounting an electrically modulated pressure control valve on the hydraulic stroker
to establish the control pressure, pump stroke is controlled by an electrical signal. At
150 to 200 mA electrical signal, the pump commences to stroke, and at approximately
390 mA, the pump will be at full stroke.
An override pressure compensator or a torque limiter control is mounted on the
on-stroke side of the control piston from the servo, hydraulic or electric stroker.The
port which connects to cylinder in the at-rest position is connected to servo, allowing
normal stroker control.When system pressure or torque exceed the override setting,
system pressure is supplied to the smaller diameter control cylinder to override the
command and reduce stroke to the compensator or torque limiter.
INTRODUCTION
ELECTRIC STROKER
PRESSURE COMPENSATOR
ANDTORQUE LIMITER
OVERRIDE
5
TROUBLESHOOTING CHART
Effect ofTrouble Possible Cause FaultWhich Needs Remedy
Compensator, Compensator Override
Low system pressure Compensator malfunction Dirt in spool orifice
Damaged cone or seat
Broken differential spring
Improperly adjusted differential spring
Failure to compensate Differential adjustment Differential set too high
Sluggish response Differential adjustment Differential set too low
Wide pressure fluctuations (hunting) Excessive line capacitance Install check valve near pump outlet
Load Sensing Control
Low system pressure See above
Failure to compensate See above
Sluggish response Differential adjustment Differential set too high
Modulating valve Air in load sensing line
Wide pressure fluctuations (hunting) Excessive line capacitance Install check valve near pump outlet
Modulating valve Air in load sensing line
Excessive pressure drop across Differential adjustment Differential set too high
control valve
Poor control of flow Differential adjustment Differential set too low
Torque Limiter, Torque Limiter Override
Torque setting erratic Torque limiter cap malfunction Sticking pin
Torque incorrect at high flows Incorrect torque setting Outer adjustment screw
Torque incorrect at low flows Incorrect torque setting Inner adjustment screw
Too much torque variation Wrong torque limiter for range Replace inner/outer springs with
correct springs
Low system pressure Compensator malfunction Dirt in spool orifice
Damaged cone or seat
Broken differential spring
Improperly adjusted differential spring
Failure to compensate Differential adjustment Differential set too high
Sluggish response Differential adjustment Differential set too low
Wide pressure fluctuations (hunting) Excessive line capacitance Install check valve near pump outlet
Rotary Servo
Failure to stroke Differential adjustment Differential set too low
Goes to full Differential adjustment Differential set too high
Sluggish response Low servo pressure Check servo pressure
Strokes in steps Servo cap malfunction Sticking pin
Wear on linkages or input cam surface
Hydraulic Stroker
Failure to stroke Differential adjustment Differential set too low
Goes to full Differential adjustment Differential set too high
Strokes in steps Servo cap malfunction Wear on linkages, Sticking stroker piston
Electric Stroker
Failure to stroke Differential adjustment Differential set too low
Goes to full Differential adjustment Differential set too high
Excessive hysteresis Electric proportional valve Change dither on electrical signal
No response Electric proportional valve Faulty wiring, Filter screen plugged
Strokes in steps Servo cap malfunction Wear on linkages
Sticking stroker piston
Instability Air in control Bleed air from control
Check for air in servo supply
General
Cannot achieve full volume Maximum volume stop Back out max. volume stop
Cannot achieve zero volume Minimum volume stop Back out min. volume stop
Noise Air in system Aerated reservoir
Leaky inlet line
Trapped air in system
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6
PRESSURE COMPENSATOR
ITEM DESCRIPTION PART NO. QTY. C10 QTY. C20
1 Max.Vol. Stop (Fig. 1) S22-12983 1 —
Max Vol. Handwheel (Fig. 2) S22-12915 — 1
2 Compensator Control (Fig. 3) S22-15312 1 1
3 Buck Up Cap (Fig. 4) S22-12970 1 1
4 Screw-H.H.C.,M12 x 60 mm 363-12210 8 6
5 Screw-H.H.C., M12 x 80 mm 363-12225 — 2
6 Control Piston 032-91443 1 1
7 O-Ring, 90 S-1 ARP 013 691-00013 2 2
8 O-Ring, 70 S-1 ARP 152 671-00152 2 2
9 Piston Ring 032-91261 2 2
CCW ROTATION
CW ROTATION
C10 C20
PRESSURE COMPENSATOR
parts list
6789
PRESSURE COMPENSATOR
ITEMS
NOT SHOWN
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PRESSURE COMPENSATOR
7
FIGURE 1
MAXIMUM VOLUME STOP
PARTS LIST FOR FIGURE 1, MAX.VOL. STOP S22-12983
ITEM DESCRIPTION PART NO. QTY.
1 Plug 10HP5N-S 488-35055 1
2 O-Ring, 90 S-1 ARP 910 691-00910 1
3 Nut, 3/4-10UNC Hex 031-91049 1
4 Screw, Soc. Set 3/4 10 x 3 311-26320 1
5 O-Ring,70 S-1 ARP 118 671-00118 1
MAXIMUM VOLUME HANDWHEEL
DISASSEMBLY
1. See Fig. 2. Remove the two screws holding the bracket (1) to the control cap.
2. Turn the handwheel counter-clockwise to remove the stop screw from the control
cap.
3. Remove nut (5) and handwheel (4) from the stop screw (2).
4. Remove nut (3). Screw (2) may now be slipped through the bracket (1) to examine
parts and to replace O-ring (6).
5. Seat (10) rotates and pivots on ball (8), and is retained by pressing two balls (9) into
screw (2). Replace assembly if damaged.
ASSEMBLY
1. Install ball (8) and seat (10) in screw (2).
2. Press balls (9) into screw (2) to retain seat.
3. Install O-ring (6) on screw (2). Lubricate O-ring and slide screw into bracket (1).
Install remaining parts.
4. Turn handwheel clockwise into cap till the screw contacts the control piston.
5. Install and Torque the assembly screws to 102 N•m
PARTS LIST FOR FIGURE 2, HANDWHEEL S22-12915
ITEM DESCRIPTION PART NO. QTY.
1 Bracket 032-91456 1
2 Screw 032-91455 1
3 Nut, Hex 3/4-16 UNC 333-25000 1
4 Handwheel 031-59911 1
5 Nut, Elastic Stop 1/2-13 331-20100 1
6 O-Ring, 90 S-1 ARP 115 691-00115 1
7 O-Ring, 90 S-1 ARP-118 691-00118 1
8 Ball 201-16001 1
9 Ball 201-04001 2
10 Seat 032-91454 1
FIGURE 2
HANDWHEEL MAXIMUM
VOLUME STOP
12 3
45
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1. See Figure 3. Back off max.volume screw or handwheel to full displacement.
Remove max. volume screw or handwheel assembly.
2. Remove bolts holding cap to pump.
3. Remove plug (15) and attached parts. Remove spring (11) and spool (18).
4. Remove adjusting plug (2) and attached parts. Remove seal piston (5). Note: a 10-
24 screw may be used to assist in pulling the piston. Remove spring (7) and cone (8).
5. Do not remove sleeve in body (1).Sleeve is pressed into cap and finished to size. If
sleeve or cap is worn, replace the cap-sleeve assembly (1).
6. Examine seat (10) for wear. Do not remove unless damaged.
1. Install Avseal plugs (9) and orifice (27) in body.
2. Press seat (10) into bore squarely against shoulder in bore.
3. Install spool (18) into bore as shown. Install spring (11) over end of spool. Install O-
ring (6) on seal (16). Lubricate and install into plug (15). Install plug (15) into cap. Install
screw (3), nut (4) and acorn nut (17).
4. Install O-ring (6) on seal piston (5).
5. Lubricate O-ring and install cone (8), spring (7) and seal piston into bore in cap (1),
being careful that cone enters seat (10). Install remaining parts.Torque plug (29) to 60
Nm.Torque plug (21) to 35 Nm.
6. Note proper location for cap on pump. Install O-rings on interface between cap and
pump control pad.
7. Install on pump control pad, guiding the control piston into the bore.Install maxi-
mum volume stop assembly.
8. Torque mounting bolts to 102 Nm.
Compensator is to be tested on pump. Adjust maximum volume stop to full displace-
ment by backing off stop till there is no contact with the control piston.
1. Install gages on system pressure and on compensator vent ports.
2. Turn compensator adjustment screw (25) CCW until there is no contact with spring,
then adjust 1/2 turn CW after contact is made with spring.
3. Turn differential adjustment screw (3) CCW until there is no contact with spring,
then adjust 1/2 turn CW after contact is made with spring.
4. System relief valve should be set at 35 bar. If testing on application, apply a load to
pump.
5. Start prime mover. Pump should be at full displacement at 35 bar.
6. Increase system relief valve until compensator de-strokes pump to zero displace-
ment. Set compensator to 103 bar.
7. Adjust compensator differential spool pressure to 13,8 bar. This is accomplished by
adjusting the differential screw until the difference in pressure readings between the sys-
tem pressure and compensator vent gages installed in the compensator cap is 13,8 bar.
(It may be necessary to change differential to gain stability. Use caution when exceeding
17 bar to avoid spring going solid, preventing compensator action.)
8. Set the compensator to 207 bar, 414 bar, and 500 bar.
9. At each condition, increase the system pressure until the pump fully de-strokes. At
no time should the system pressure vary more than 10,3 bar from the compensator set-
ting.The control should be steady and stable at all conditions.
10. Reduce pressure to 10,3 bar below the compensator setting.Pump should return to
full stroke. Repeat two or more times. Compensator setting should be repeatable.
11. Set compensator adjustment to the required setting, or 414 Bar if not otherwise
noted.
PRESSURE COMPENSATOR
COMPENSATOR DISASSEMBLY
ASSEMBLY
COMPENSATOR TEST AND
ADJUSTMENT
8
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PARTS LIST FOR FIGURE 3
compensator S22-15312 ITEM DESCRIPTION PART NO. QTY.
1 Cap-Sleeve Assembly S22-12881 1
2 Adj. Plug 032-91814 1
3 Soc. Setscrew 5/16-24 x 1 312-13160 1
4 Nut, 5/16-24 335-13100 2
5 Seal Piston 031-59367 1
6 O-Ring, 90 S-1 ARP 012 691-00012 2
7 Spring 032-91798 1
8 Cone 036-12288 1
9 Avseal Plug 447-00026 2
10 Seat 036-11692 1
11 Spring 033-71086 1
13 O-Ring, 90 S-1 ARP 910 691-00910 1
14 O-Ring, 90 S-1 ARP 017 691-00017 1
15 Plug 031-57368 1
16 Seal Piston 032-91305 1
17 Nut, Acorn 5/16-24 327-25006 1
18 Spool 032-59482 1
19 Orifice Plug 033-25528 1
21 Plug, BSPP 3/8 447-00032 1
25 Soc. Setscrew 5/16-24 x 1-1/4 312-13180 1
26 Acorn Nut 036-33474 1
28 Plug, BSPP 1/4 447-01004 1
29 Plug, BSPP 1/2 447-01008 1
PRESSURE COMPENSATOR
9
FIGURE 3
COMPENSATOR
29
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1. See Figure 4 Set maximum volume stop to full stroke.Remove 4 screws holding cap
to pump. Caution! Spring load could cause injury!
2. Remove cap assembly from pump.
3. Remove and examine spring (2) and pin (1). If snout (3) is worn, press it out and
replace.
1. Install Avseal plug (7) into cap.Press snout (3) into cap to shoulder. Install pin (1), O-
ring (5) and plug (6) into cap. Torque plug to 190 Nm.
2. Install O-rings on interface between cap and pump control pad. Install spring (2) into
control piston.Install cap assembly on pump housing as indicated on the applicable view,
guiding the control piston into the bore.
3. Torque the assembly bolts to 102 Nm.
ITEM DESCRIPTION PART NO. QTY.
1 Pin 324-24048 1
2 Spring 032-91273 1
3 Snout 032-91344 1
4 Control Cap 032-91266 1
5 O-Ring, 90 S-1 ARP 916 691-00916 1
6 Plug 16 HP5N-S 488-35024 1
7 Avseal Plug 447-00026 1
FIGURE 4
BUCK-UP CAP
BUCK-UP CAP DISASSEMBLY
ASSEMBLY
PARTS LIST FOR FIGURE 4
buck-up cap S22-12983
PRESSURE COMPENSATOR
10
TORQUE 190 Nm
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P140 P260 QUANTITY
ITEM DESCRIPTION PART NO. PART NO. E10 E1J E1K E1P
1 Electric Stroker (Fig. 5) S22-15306 S22-15306 1 1 1 1
2 Control Cap (Fig. 7) S22-15272 S22-15272 1 — — —
Low Torque Override (Fig. 8) S22-15650 S22-15533 — 1 — —
High Torque Override (Fig. 8) S22-15651 S22-15535 — — 1 —
Compensator Override (Fig. 10) S22-15531 S22-15531 — — — 1
*3 O-Ring, 90 S-1 ARP 113 691-00113 691-00113 2 2 2 2
*4 Elbow 494-15019 494-15019 1 1 1 1
*5 Elbow 494-15021 494-15021 1 1 1 1
*6 450Swivel Nut Ell 492-15389 492-15389 1 1 1 1
*7 Tube 032-91888 032-92190 1 1 1 1
8 Screw-H.H.C., M12 x 60 mm 363-12210 363-12210 6 4 4 6
9 Screw-H.H.C., M12 x 80 mm 363-12225 363-12225 2 4 4 2
10 Control Piston 032-91785 032-91785 1 1 1 1
11 O-Ring, 90 S-1 ARP 013 691-00013 691-00013 2 2 2 2
12 O-Ring, 70 S-1 ARP 152 671-00152 671-00152 2 2 2 2
13 Piston Ring 032-91261 032-91261 1 1 1 1
14 Piston Ring 032-91811 032-91811 1 1 1 1
*Tubing assembly available as S22-15583 (P260)
*Tubing assembly available as S22-15668 (P140)
11
ELECTRIC STROKER
ELECTRIC STROKER
parts list
8
2
7
4
1
9
3
356
7
4
1
9
3
356
8
2
NOT SHOWN
8
7
4
1
3
356
2
9
2
7
43
8
1
9
356
7
43
2
1
9
356
9
8NOT SHOWN
356
1
9
7
43
8
2
E10 E1J – E1K
CW ROTATION
CCW ROTATION
E1P
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1. See Figure 5. Remove 3 screws (37) holding block (36) to body (16).
2. Remove 2 screws holding body (16) to cap assembly (1).
3. Remove all parts from body (16) except pin (30) and arm assembly (28). It is not
necessary to remove these parts unless broken or worn. Examine parts for wear or
damage.
4. Remove screw (3). Examine head for excessive wear, and body for smooth sealing
surface with O-ring.
5. See Figure 6. Remove tube lines to cap assembly.
6. Remove screws holding cap assembly to pump body.
7. Remove cap assembly (1). Remove plug (3) with attached parts. Remove spring
(8) and spool (4).
8. Do not remove sleeve in body (1). Sleeve is pressed into cap and finished to size.
If sleeve or cap is worn, replace the cap-sleeve assembly (1).
9. Remove screw (14) and nut (15). Push a rod through the cap to remove the
retainer (12).
1. See Figure 6. Install Avseal plug (6) in cap.
2. Install spool (4) into bore as shown. Install spring (8) over end of spool.
3. Install O-ring (13) on spring retainer (12). Install retainer (12), screw (14), and nut
(15) in plug (3).
4. Install O-rings (7) and (16) on plug (3). Install plugs (3) and (9) in body (1).Torque
plugs to 60 Nm. Install O-ring (8) in cap.
5. Turn screw (15) in until spring retainer (12) contacts spring (8). Turn an additional
1-1/2 turns and lock in position.
6. Note proper location for control on pump. Install O-rings on interface between cap
and pump control pad. Install cap on pump control pad, guiding the control piston into
the bore.
7. Torque two assembly bolts to 102 Nm.
8. See Figure 5. Apply Loctite®on threads of screw (3), lubricate the shank, thread
through the cap into the control piston, and torque to 6,78 Nm.
9. Install minimum stop screw (24) and turn clockwise to stroke pump to full volume.
Measure height from control cap to top of screw (3).With control piston at full stroke,
dimension must be 11,4 +/- 0,76 mm. Back out minimum stop screw (24) till there is no
contact with control piston.
10. Press dowel (30) into body (16), through the link (28), to 6,35 mm below surface,
apply Loctite®to threads of screws (46) and install over dowel (30).
11. Press spool (21) into retainer (19). Caution: do not use excessive force. Place
spool/retainer assembly into spool (17) with spring (18) and washer (34). Secure with
retaining ring (33).
12. While sleeve (27) is engaged into dowel on link (28), slide above spool assembly
into bore of body (16), and through sleeve (27). Spool (21) must move freely and easily
at all positions of the link (28).
13. Install one orifice (40) in the tapped hole in the block (36). Install the other on top
of the first.Torque to 7,9 Nm.
14. Install proportional valve (41) in block.Torque to 27 Nm.
15. Install coil on proportional valve.Torque to 2,2-2,8 Nm max.
16. Assemble all other components into body (16) per above drawing.Torque the plug
(12) to 122 Nm.
17. While spring retainer is engaging clevis pin (5) under dowel of link (28), slide the
other opening of spring retainer over the top of the screw (3). Attach body assembly
(16) to cap (1) with two screws and torque to 103 Nm.
1. Plumb 82,8 bar servo supply to control. Supply 82,8 bar to the electric stroker
servo supply port. Note: All pressure references are “above case pressure” (1,7 bar
max.)
2. Thread zero screw (24) so that pump is on stroke.
3. Place a gage in the proportional valve gage port.
4. Start pump.
ELECTRIC STROKER
ELECTRIC STROKER
DISASSEMBLY
ASSEMBLY
TEST AND ADJUSTMENT
12
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5. Adjust amperage (150 to 200 mA) to give 34,5 bar reading on the proportional
valve gage port. Back out zero screw (24) and adjust screw (9) until output flow is at
zero stroke position. Lock both adjustments in place.
6. Increase amperage to 390 mA. Pump should go to full stroke. Set max. volume
screw on opposide control cap for full stroke. Gage in proportional valve gage port
should read approximately 18,6 bar.
7. If pump fails to go towards full stroke, or fails to go towards zero stroke, differential
pressure may be improperly adjusted. Re-adjust the screw (15 figure 6) out to go
towards full or in to go towards zero flow.
8. Increase and decrease the amperage between 0 and 390 mA several times at
approximately 34,5 bar, 207 bar and 414 bar system pressure. Pump stroke should fol-
low amperage smoothly and proportionally. Full to zero or zero to full stroke should be
achieved in .5 second. Adjust amperage up to 275 mA from zero stroke, then adjust
down from full stroke to 275 mA. The flows at the two 275 mA settings shall not vary
more than 18.9 l/m from each other.
ELECTRIC STROKER
13
FIGURE 6
SERVO CAP
102 Nm
48
41 42 43
LOCTITE®271
46
37
36
49
50
40
35
46
LOCTITE®271
4445
102 Nm
FIGURE 5
ELECTRIC STROKER
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ITEM DESCRIPTION PART NO. QTY.
1 Cap (Figure 6) S22-15268 1
3 Screw 032-91461 1
4 O-Ring, 70 S-1 ARP 010 671-00010 1
5 Clevis pin 321-40000 1
6 Spring, Compression 032-92100 1
7 Plug, Avseal 447-00026 1
8 Nut, 5/16-24 335-13100 1
9 Soc. Setscrew, 5/16-24 x 1-1/4 312-13180 1
10 Seal Piston 032-91918 1
11 O-Ring, 90 S-1 ARP 012 691-00012 1
12 Plug, 10HP5N-S 488-35055 1
13 O-Ring, 90 S-1 ARP 910 691-00910 1
14 Spring Cap 032-91511 1
15 Spring 225-92101 1
16 Body S22-15393 1
17 Spool 032-91512 1
18 Spring 225-92109 1
19 Spring Retainer 032-91516 1
20 Nut, 3/4-10 031-91049 1
21 Spool 032-91438 1
23 O-Ring,70 S-1 ARP 118 671-00118 1
24 Soc. Setscrew, 3/4-10 x 3 311-26320 1
25 Plug, 12 HP5N-S 488-35014 1
26 O-Ring, 90 S-1 ARP 912 691-00912 1
27 Sleeve 032-91437 1
28 Arm assembly S22-15520 1
29 O-Ring, 70 S-1 ARP 035 671-00035 1
30 Dowel Pin, 1/8 Dia x 1.75 Lg. 324-20828 1
33 Ret. Ring 356-30037 1
34 Washer 032-91517 1
35 O-Ring, 70 S-1 ARP 011 671-00011 2
36 Block 032-91509 1
38 Plug, 7/16-20 449-00013 1
39 O-Ring, 90 S-1 ARP 908 691-00908 1
40 Orifice, 635 mm 033-91225 2
41 Prop. Pr. Cont.Valve 517-00085 1
42 Coil, 24VDC 517-00086 1
43 Connector 167-01008-8 1
44 O-Ring, 90 S-1 ARP 904 691-00904 2
45 Plug, SAE-4 488-35061 1
46 Screw, SHC 10-32 x 1/4 312-09041 2
48 Plug 449-00599 1
49 Adapter SAE-4/BSP 1/4 492-15379 1
50 Seal 449-00603 1
ITEM DESCRIPTION PART NO. QTY.
1 Cap/Sleeve S22-15267 1
2 Plug 449-00599 2
3 Plug 032-91861 1
4 Spool 032-91820 1
5 O-Ring, 70 S-1 ARP 008 671-00008 1
6 Avseal Plug 447-00026 1
7 O-Ring, 90 S-1 ARP 910 691-00910 1
8 Spring 032-91863 1
9 Plug, BSPP 1/2 447-01008 1
10 Plug, BSPP 1/4 447-01004 1
12 Spring retainer 032-91862 1
13 O-Ring, 90 S-1 ARP 013 691-00013 1
14 Screw, 5/16 -24 x 1 312-13160 1
15 Nut, 5/16-24 335-13100 1
16 O-Ring, 90 S-1 ARP 017 691-00017 1
ELECTRIC STROKER
PARTS LIST FOR FIGURE 5
electric stroker S22-15306
PARTS LIST FOR FIGURE 6
servo cap S22-15268
14
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ELECTRIC STROKER
CONTROL CAP DISASSEMBLY
ASSEMBLY
PARTS LIST FOR FIGURE 7
control cap assembly S22-15272
15
FIGURE 7
CONTROL CAP ASSEMBLY
ITEM DESCRIPTION PART NO. QTY.
1 Control Cap 032-91766 1
2 Plug 449-00599 1
3 O-ring, 70 S-1 ARP 118 671-00118 1
4 Screw, 3/4-10 x 3 311-26320 1
5 Nut 031-91049 1
6 Plug 488-35055 1
7 O-ring 90 S-1 ARP 910 691-00910 1
1. See Figure 7. Remove cover (5) and Max.volume screw (4).
2. Remove 4 screws holding cap to pump.
3. Remove cap assembly from pump.
1. Install O-rings on interface between cap and pump control pad. Install cap on pump
housing as indicated on the applicable view, guiding the control piston into the bore.
2. Torque the assembly bolts to 102 Nm.
3. Install screw (4) in cap. Install O-ring (3) on nut (5). Install nut (5) on screw.
3. Adjust screw till pump is slightly on stroke and lock nut (5).
4. Install O-ring (7) on plug (6). Install plug in nut (5).Torque plug (6) to 68 Nm.
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1. See figure 8. Remove 2 screws holding torque limiter body (16) to cap assembly
(1).
2. Remove all parts from torque limiter body (16) except pin (30) and arm assembly
(28). It is not necessary to remove these parts unless broken or worn. Examine parts for
wear or damage.
3. Remove screw (3). Examine head for excessive wear, and body for smooth sealing
surface with O-ring.
4. See figure 9. Remove maximum volume stop assembly (items 19, 20, 21, 22, 27).
5. Remove cap assembly (1).
6. Remove plug (15) and attached parts. Remove spring (11) and spool (18).
7. Remove adjusting plug (2) and attached parts. Remove seal piston (5).Note: a
10-24 screw may be attached to assist in pulling the piston. Remove spring (7) and
cone (8).
8. Do not remove sleeve in body (1). Sleeve is pressed into cap and finished to size. If
sleeve, snout or cap is worn, replace the cap-sleeve assembly (1).
9. Examine seat (10) for wear. Do not remove unless damaged.
1. See figure 9. Install Avseal plugs (9) and orifice (32).
2. Press seat (10) into bore squarely against shoulder in bore.
3. Install spool (18) into bore as shown. Install spring (11) over end of spool. Install O-
ring (6) on seal (16). Lubricate and install into plug (15). Install O-rings (13) and (14) on
plug (15) Install plug (15) into cap. Install screw (3), nut (4) and acorn nut (17).
4. Install O-ring (6) on seal piston (5).
5. Lubricate O-ring and install cone (8), spring (7) and seal piston into bore in cap (1),
being careful that cone enters seat (10). Install adj. plug (2), screw (25), nut (4), and
acorn nut (25).
6. Install plug (12) and torque to 60 Nm. Install plug (21).Torque to 35 Nm.
7. Carefully install O-ring (31) into the cap.
8. Note proper location for cap. Install O-rings on interface between cap and pump
control pad. Install cap assembly on pump, guiding the control piston into the bore.
Torque two mounting screws to 101 Nm.
9. Install maximum stop screw (20), cover (19) ,O-ring (30) and plug (29) with O-ring
(24).
10. See figure 8. Apply Loctite®on threads of screw (3), lubricate the shank, thread
through the cap into the control piston, and torque to 6,78 Nm.
11. Measure height from control cap to top of screw. With control piston at zero stroke,
dimension must be 11,4 +/- 0,76 mm.
12. Press dowel (30) into body (16), through the link assembly (28), to 6,35 mm below
surface. Apply Loctite®to threads of screws (33) and install over dowel (30).
13. While sleeve (27) is engaged into dowel on link (28), slide spool (21) into bore of
body (16), and through sleeve (27). Spool (21) must move freely and easily at all posi-
tions of the link (28).
14. Assemble remaining parts per drawing.Torque plug (11) to 68 Nm.
15. While spring retainer is engaging screw (5) under dowel of link (28), slide the other
opening of spring retainer over the top of the screw (3). Attach body assembly (16) to
cap (1) and torque assembly screws to 102 Nm.
ELECTRIC STROKER
TORQUE LIMITER OVERRIDE
DISASSEMBLY
ASSEMBLY
16
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ELECTRIC STROKER
17
FIGURE 8
TORQUE LIMITER OVERRIDE
HIGH FLOW
PRESSURE
ADJUST.
TORQUE
68 Nm
HIGH PRESSURE
FLOW
ADJUST.
LOCTITE®271
TORQUE
6,78 Nm
NOT SHOWN
(LOCTITE®271)
33
ITEM DESCRIPTION PART NO. QTY. **J QTY. **K
1 Cap (Figure 9) S22-15275 1 1
3 Screw 032-91461 1 1
5 Clevis pin 321-40000 1 1
6 Spring, Compression 032-92100 1 1
7 Plug, Avseal 447-00026 1 1
8 Screw 032-91445 1 1
9 Nut, Hex Jam 1/4-20 UNC 340-00038 1 1
10 Hex Nut, 3/4-16 UNF 032-91449 1 1
11 Plug, 8HP N-S 488-35018 1 1
14 O-Ring, 90 S-1 ARP 908 691-00908 1 1
15 Screw, Primary Adjust 032-91446 1 1
16 Body assembly S22-15397 1 1
17 Outer Spring – J Version 032-91440 1 —
Outer Spring – K Version 032-91448 — 1
18 Inner Spring – J Version 032-91441 1 —
Inner Spring – K Version 032-91447 — 1
19 Spring Retainer 032-91819 1 1
21 Spool 032-91438 1 1
23 O-ring, 70 S-1 ARP 118 671-00118 2 2
25 Plug, 12 HP5N-S 488-35014 1 1
26 O-Ring, 90 S-1 ARP 912 691-00912 1 1
27 Sleeve 032-91437 1 1
28 Arm assembly S22-15520 1 1
29 O-Ring, 70 S-1 ARP 035 671-00035 1 1
30 Dowel Pin, 1/8 Dia. x 1.75 Lg. 324-20828 1 1
33 Screw, SHC 10-32 x 1/4 312-09041 2 2
34 Nut 032-91645 1 1
35 O-Ring, 70 S-1 ARP 010 671-00010 1 1
PARTS LIST FOR FIGURE 8
torque limiter override
code J S22-15533
code K S22-15535
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ITEM DESCRIPTION PART NO. QTY.
1 Cap-Sleeve Assembly S22-15280 1
2 Adj. Plug 032-91814 1
3 Soc. Setscrew 5/16-24 x 1 312-13160 1
4 Nut, 5/16-24 335-13100 2
5 Seal Piston 031-59367 1
6 0-Ring, 90 S-1 ARP 012 691-00012 2
7 Spring 032-91798 1
8 Cone 036-12288 1
9 Avseal Plug 447-00026 2
10 Seat 036-11692 1
11 Spring 033-71086 1
12 Plug, BSPP 1/2 447-01008 1
13 O-Ring, 90 S-1 ARP 910 691-00910 1
14 O-Ring, 90 S-1 ARP 017 691-00017 1
15 Plug 031-57368 1
16 Seal Piston 032-91305 1
17 Nut, Acorn 5/16-24 327-25006 1
18 Spool 032-91820 1
19 Cover 032-91761 1
20 Screw, 1/2-20 x 2-1/2 312-35060 1
21 Plug 447-00032 1
23 Soc. Setscrew 5/16-24 x 1-1/4 312-13180 1
24 O-Ring, 70 S-1 ARP 015 671-00015 1
25 Acorn Nut 036-33474 1
26 Plug 449-00599 1
27 Plug, BSPP 1/4 447-01004 1
28 Plug, BSPP 1/2 447-01008 1
29 Plug 488-35020 1
30 O-Ring, 90 S-1 ARP 905 691-00905 1
31 O-Ring, 70 S-1 ARP 008 671-00008 1
32 Orifice 035-40489 1
PARTS LIST FOR FIGURE 9,
torque limiter override cap S22-15275
18
FIGURE 9
TORQUE LIMITER OVERRIDE CAP
25
31
1
18
SYSTEM
PRESS.
SAE-10 TORQUE
60 Nm
TORQUE
30 Nm
VENT CONN.
TORQUE
35 Nm
DIFFERENTIAL
ADJUSTMENT
COMPENSATOR
ADJUSTMENT
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1. Install gages on system pressure and on compensator vent ports.
2. Turn compensator adjustment screw out to remove spring load, then 1/2 turn in.
3. Turn differential adjustment screw out to remove spring load, then 1/2 turn in.
4. Back out maximum volume stop to full volume.
5. For setting and testing compensator override function, disable torque limiter in this
manner: Back out primary adjusting screw (15) figure 8, to remove all load.Turn in outer
adjusting screw (8) to go solid.Caution! do not apply over 1,2 Nm torque to avoid damage
to internal parts!
6. Start prime mover with system relief set at 35 bar.
7. Stroke pump to full displacement.Apply a load to the pump.
8. Increase system relief valve until compensator de-strokes pump to zero displace-
ment. Set compensator to 103 bar.
9. Adjust compensator differential spool pressure to 13,8 bar. This is accomplished by
adjusting the differential screw until the difference in pressure readings between the sys-
tem pressure and compensator vent gages installed in the compensator cap is 13,8 bar.
(It may be necessary to change differential to gain stability. Use caution when exceeding
17 bar to avoid spring going solid, preventing compensator action.)
10. Set the compensator to 207 bar, 414 bar, and 500 bar.At each condition, increase the
system pressure until the pump fully de-strokes. At no time should the system pressure
vary more than 10,3 bar from the compensator setting.The control should be steady and
stable at all conditions.
11. Reduce pressure to 10,3 bar below the compensator setting. Pump should return to
full stroke. Repeat two or more times. Compensator setting should be repeatable.
12. Set compensator adjustment to at least 34,5 bar above the required setting, or 483
bar.
Set the torque limiter by using the formula:
kW = P•Q/(Eff.• 600)
where P = pressure in Bar
Q = flow in l/m
calculate these two values:
a. System pressure at full pump flow.
b. Pump flow at full system pressure.
13. Set system relief valve to pressure (a) calculated above. Back out primary adjusting
screw to remove all load. Set outer adjusting screw (8) so that pump just commences to
de-stroke.
14. Set the system relief valve to the required maximum system pressure. Set primary
adjusting screw (15) to obtain the calculated flow (b) at full system pressure.
15. Set compensator adjustment to the required setting, or 414 bar if not otherwise noted.
Note: Electric motor current may be used instead of calculated flows to set power. In step
13, set the outer adjusting screw (8) to achieve the rated motor current. In step 14, set
the adjustment (15) to achieve the rated motor current.
TORQUE LIMITER OVERRIDE
TEST AND ADJUSTMENT
19
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1. See Figure 10. Remove tube line to cap.
2. Remove maximum volume stop assembly (items 12, 13, 19, 20, 24).
3. Remove cap assembly.
4. Remove plug (15) and attached parts. Remove spring (11) and spool (18).
5. Remove adj. plug (2) and attached parts. Remove seal piston (5). Note: a 10-24
screw may be attached to assist in pulling the piston. Remove spring (7) and cone (8).
6. Do not remove sleeve in body (1). Sleeve is pressed into cap and finished to size.
If sleeve, snout or cap is worn, replace the cap-sleeve assembly (1).
7. Examine seat (10) for wear. Do not remove unless damaged.
1. Install Avseal plugs (9) in body. Install orifice (29) in body.
2. Press seat (10) into bore to shoulder in bore.
3. Install spool (18) into bore as shown. Install spring (11) over end of spool. Install
O-ring (6) on seal (16). Lubricate and install into plug (15). Install O-rings (13) and (14)
on plug (15). Install plug (15) into cap. Install screw (3), nut (4) and acorn nut (17).
4. Install O-ring (6) on seal piston (5).
5. Lubricate O-ring and install cone (8), spring (7) and seal piston into bore in cap (1),
being careful that cone enters seat (10).
6. Install remaining parts.Torque plug (12) to 68 Nm.Torque plug (21) to 35 Nm.
7. Note proper location for cap on pump. Install O-rings on interface between cap and
pump control pad.
8. Install cap assembly on pump, guiding the control piston into the bore.
9. Torque mounting bolts to 102 Nm.
10. Install tube fitting and tube line connecting to opposite cap.
Compensator is to be tested on pump. Adjust maximum volume stop to full displace-
ment.
1. Install gages on system pressure and on compensator vent ports.
2. Turn compensator adjustment screw (23) CCW until there is no contact with spring,
then adjust 1/2 turn CW after contact is made with spring.
3. Turn differential adjustment screw (3) CCW until there is no contact with spring,
then adjust 1/2 turn CW after contact is made with spring.
4. Start prime mover with system relief valve set at 35 bar. Apply a load to the pump.
5. Set pump control to full displacement. Pump should go to full displacement at 35
bar.
6. Increase system relief valve until compensator de-strokes pump to zero displace-
ment. Set compensator to 103 bar.
7. Adjust compensator differential spool pressure to 13,8 bar. This is accomplished by
adjusting the differential screw until the difference in pressure readings between the sys-
tem pressure and compensator vent gages installed in the compensator cap is 13,8 bar.
(It may be necessary to change differential to gain stability. Use caution when exceeding
17 bar to avoid spring going solid, preventing compensator action.)
8. Set the compensator to 207 bar, 414 bar, and 500 bar.
9. At each condition, increase the system pressure until the pump fully de-strokes. At
no time should the system pressure vary more than 10,3 bar from the compensator set-
ting.The control should be steady and stable at all conditions.
10. Reduce pressure to 10,3 bar below the compensator setting.Pump should return to
full stroke. Repeat two or more times. Compensator setting should be repeatable.
11. Set compensator adjustment to the required setting, or 414 bar if not otherwise
noted.
ELECTRIC STROKER
COMPENSATOR OVERRIDE
DISASSEMBLY
ASSEMBLY
TEST AND ADJUSTMENT
20
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