Denison Hydraulics Premier Series Operating and installation instructions

DENISON HYDRAULICS
Premier Series
open loop pump controls
series P080
service information
Publ. S1-AM027
Internet: http://www.denisonhydraulics.com E-mail: denison@ denisonhydraulics.com
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CONTENTS
2
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-------------------------------------------------------------------------
Pump seal kit (includes all controls) S22-15647 See key sheet pg. 45 for information
PAGE
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3
CHARACTERISTICS
Specification
• compensator response off-stroke
on-stroke
(per SAE J745 Apr. 87 at 345 bar)
• compensator adjustment
• minimum compensating pressure (comp, load
sensing, torque limiter)
• minimum servo pressure for 500 bar system
pressure
• minimum compensator override pressure at 48,3
bar servo pr. (servo, elec. & 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
• torque to turn rotary servo shaft
• hydraulic stroker control pressure 0 disp.
full disp.
• electric stroker control amps (24V) 0 disp.
full disp.
• electric stroker control amps (12V) 0 disp.
full disp.
pulse width modulation frequency:
Denison Hydraulics electric stroker accessories
mating connector: Din 43650 type AF part no.
167-10008-8 (provided)
Jupiter driver S20-14078
Jupiter power supply S20-11715
Options card S20-ll716
Venus controller 020-14103
• 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
• 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)
NOTES
*on-stroke response for compensator override is
determined by servo/stroker response.
**add case pressure
Term
sec.
sec.
bar/turn
bar
bar
bar
Nm
Nm
sec.
l/min.
l/min
bar
degrees
cc/rev/deg.
Nm
bar
bar
mA
mA
mA
mA
Hz
ohms
ohms
turns
Nm
Nm
BSPP
BSPP
BSPP
BSPP
BSPP
BSPP
P080
0,060
0,110*
138
13,8**
48,3**
84,5**
90 - 170
over 170
<0,35
11,4
15,2
103
56
1,43
2,3
3,45
14,5
125
290
250
580
100-150
41
10
9
9
20
1/4
1/4
1/4
1/4
3/8
3/8
TYPICAL CHARACTERISTICS
FLUID CONNECTIONS
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The instructions contained in this manual cover complete disassembly and reassembly of the con-
trols. 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,. A spring on this end biases the spool to normally port the control piston to pump case .
This control piston links to the pump cam. On the opposite side of the control piston, a spring and
a piston connected to system pressure along with pump timing forces, 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 pressure reaches this value, flow
through the spool creates a pressure difference across the spool. At approximately 13,8 bar differ-
ence, the spool shifts toward the spring, re-directing the control cylinder port to pressure. This pres-
sure applied to the control piston 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
maintain the pump pressure at approximately 13,8 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. Flow through this port, when controlling, is approximately 1,9 l/m.
For load sensing, this “V” port is connected to the load. The valve between the pump and the load
meters the flow. The pump provides the flow to develop 13,8 bar drop across the valve indepen-
dent of the load pressure and thus establishes a constant flow 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 is unacceptable, and where multiple loads are to be
controlled, a load sensing control is available. In the load sensing control, the vent flow is modulat-
ed 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 constant torque, system pressure and pump displacement are interrelated by the formula
P•V=C. As pressure increases, displacement must reduce, and vice versa.
A linkage to the pump control piston slides a spool over a pin.. 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 piston, reducing stroke. The linkage to the control piston
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 piston. The position of the pin is deter-
mined 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 theP•V=C relation-
ship. 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 piston. The control piston
has a large diameter on this side, and a smaller diameter on the opposite 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, this end of the control piston is ported to tank, and servo pres-
sure 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 piston
causing the cam to shift towards full stroke.
The pin as described for the torque limiter, is spring loaded against a mechanism which converts
rotary motion of the input shaft to linear motion of the pin, thus positioning pump stroke proportion-
ately to input shaft rotation.
In the hydraulic stroker, a spring loaded piston is attached to this 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 stroke in proportion to control pressure. Full stroke is
achieved at 14,5 bar control pressure.
INTRODUCTION
GENERAL
DESCRIPTION OF OPERATION
PRESSURE COMPENSATOR
PRESSURE COMPENSATOR
LOAD SENSING CONFIGURA-
TION
LOAD SENSING CONTROL
TORQUE LIMITER
ROTARY SERVO CONTROL
HYDRAULIC STROKER
4
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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 approximately 125 mA
electrical signal, the pump commences to stroke, and at approximately 290 mA, the pump will be
at full stroke. The Denison Hydraullics Venus controller 020-14103, Jupiter S20-14078, or Jupiter
S20-14087 may be used to drive the electric stroker.
An override pressure compensator or torque limiter control is mounted on the on-stroke side of the
control piston opposite the servo, hydraulic or electric stroker. The port on the override control
which normally 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 piston to override the command and reduce stroke to the
compensator or torque limiter setting.
INTRODUCTION
ELECTRIC STROKER
PRESSURE COMPENSATOR
AND TORQUE LIMITER OVER-
RIDE
5
TROUBLESHOOTING CHART
Effect of Trouble Possible Cause Fault Which 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
P080 QTY.
ITEM DESCRIPTION . PART NO. C10 C20
1Max. Vol. Stop (Fig. 1) S22-15467 1 —
Max Vol. Handwheel (Fig. 2) S22-15448 — 1
*2 Compensator Control (Fig. 3) S22-15623 1 —
Compensator Control S22-15633 — 1
3 Buck Up Cap (Fig. 4) S22-15447 1 1
4 Screw-H.H.C.,M12 x 55 mm 363-12205 8 6
5Screw-H.H.C., M12 x 75 mm 363-12220 — 2
6Control Piston 032-91836 1 1
7 O-Ring, 70 S-1 ARP 013 671-00013 2 2
8 O-Ring, 70 S-1 ARP 151 671-00151 2 2
9 Piston Ring 032-91816 2 2
*includes items 1, 4, 5
C10 C20
PRESSURE COMPENSATOR
parts list
1
2
4
3
4
3
1
4
2
4
1
5
2
3
4
3
5
1
2
4
6 7 8 9
ITEMS
NOT SHOWN
CCW ROTATION
CW ROTATION
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PRESSURE COMPENSATOR
7
FIGURE 1
MAXIMUM VOLUME STOP
PARTS LIST FOR FIGURE 1, MAX. VOL. STOP S22-15467
ITEM DESCRIPTION PART NO. QTY.
1 Plug 8HP5N-S 488-35018 1
2 O-Ring, 90 S-1 ARP 908 691-00908 1
3 Nut, M16 Hex 032-91822 1
4 Screw, Soc. Set 311-50001 1
5 O-Ring,70 S-1 ARP 115 671-00115 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 Nm.
PARTS LIST FOR FIGURE 2, HANDWHEEL S22-15448
ITEM DESCRIPTION PART NO. QTY.
1 Bracket 032-92056 1
2 Screw 032-92057 1
3 Nut, Hex 3/4-16 UNC 333-25000 1
4 Handwheel 031-59911 1
5Nut, Elastic Stop 1/2-13 331-20100 1
6O-Ring, 90 S-1 ARP 115 691-00115 1
7O-Ring, 90 S-1 ARP-118 691-00118 1
8Ball 201-12001 1
9 Ball 201-04001 2
10 Seat 032-92058 1
FIGURE 2
HANDWHEEL MAXIMUM
VOLUME STOP
12
3
4
5
54
3
6
1
7
8
10
2
9
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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 (19) in body.
2. Press seat (10) into bore squarely against shoulder in bore.
3. Install O-ring (14) in bottom of bore as shown. Install spool (18) into bore as
shown. Install spring (11) over end of spool. Install O-ring (6) on seal piston (16). Lubri-
cate and install into plug (15). Install O-ring (13) on plug (15). Install plug (15) into cap.
Install screw (3) and nut (4).
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 (12) to 60
Nm. Torque plug (27) to 35 Nm. Torque plug (28) to 30 Nm.
6. Note proper location for cap on pump. Install O-rings on interface between cap and
pump control pad.
7. Install cap on pump control pad, guiding the control piston into the bore. Install
maximum 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 or load until compensator de-strokes pump to zero dis-
placement. 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. Install cap (17) on differential adjustment.
PRESSURE COMPENSATOR
COMPENSATOR DISASSEMBLY
ASSEMBLY
COMPENSATOR TEST AND
ADJUSTMENT
8
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PARTS LIST FOR FIGURE 3
compensator C10, S22-15623
compensator C20, S22-15633
ITEM DESCRIPTION PART NO. QTY.
1Cap-Sleeve Assembly S22-15604 1
2 Adj. Plug 032-91814 1
3Soc. Setscrew 5/16-24 x 1 312-13160 1
4 Nut, 5/16-24 335-13100 2
5Seal 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
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 Cap 449-00612 1
18 Spool 032-59482 1
19 Orifice Plug 033-25528 1
25 Soc. Setscrew 5/16-24 x 1-1/4 312-13180 1
26 Acorn Nut 036-33474 1
27 Plug, BSPP 3/8 447-00032 1
28 Plug, BSPP 1/4 447-01004 2
PRESSURE COMPENSATOR
9
FIGURE 3
COMPENSATOR
COMPENSATOR
ADJUSTMENT
DIFFERENTIAL
ADJUSTMENT
CONTROL PRESS.
PORT 1/4 BSPP
TORQUE 30 Nm
COMPENSATOR
VENT 3/8 BSPP
TORQUE 35 Nm
SYSTEM PRESSURE
1/2 BSPP
TORQUE 60 Nm
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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 piston (1). If sleeve (3) is worn, press it out and
replace.
1. Install Avseal plug (7) into cap. Press sleeve (3) into cap to shoulder. Install O-ring (5)
and plug (6) into cap. Torque plug to 190 Nm. Install spring (2) and piston (1).
2. Install O-rings on interface between cap and pump control pad. 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.
P080
ITEM DESCRIPTION PART NO. QTY.
1 Piston 032-92202 1
2 Spring 032-92205 1
3 Sleeve 032-92203 1
4 Control Cap 032-91832 1
5 O-Ring 691-00920 1
6 Plug 032-92204 1
7 Avseal Plug 447-00026 1
FIGURE 4
BUCK-UP CAP
BUCK-UP CAP DISASSEMBLY
ASSEMBLY
PARTS LIST FOR FIGURE 4
P080 buck-up cap S22-15447
PRESSURE COMPENSATOR
10
1
2
3
5
7
6
4
TORQUE 190 Nm
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11
ELECTRIC STROKER
P080 QUANTITY
ITEM DESCRIPTION . PART NO. E10 E1J E1K E1P
1Electric Stroker (Fig. 5) S22-15610 1 1 1 1
2Control Cap (Fig. 7) S22-15613 1 — — —
Low Torque Override (Fig. 8) S22-15615 — 1 — —
High Torque Override S22-15632 — — 1 —
Comp. Override (Fig. 10) S22-15614 — — — 1
*3 O-Ring, 90 S-1 ARP 113 691-00113 2 2 2 2
*4 Elbow 494-15019 2 2 2 2
*5 Tube, CW 032-92250 1 1 1 1
Tube, CCW 032-92251
**6 Screw-H.H.C., M12 x 55 mm 363-12205 6 4 4 6
**7 Screw-H.H.C., M12 x 75 mm 363-12220 2 4 4 2
8Control Piston 032-91785 1 1 1 1
9 O-Ring, 70 S-1 ARP 013 671-00013 2 2 2 2
10 O-Ring, 70 S-1 ARP 151 671-00151 2 2 2 2
11 Piston Ring 032-91816 1 1 1 1
12 Piston Ring 032-91811 1 1 1 1
*Tubing assembly including items 3, 4, and 5 are available as S22-15605 (CW),
S22-15606 (CCW)
**Included with items 1, 2
ELECTRIC STROKER
parts list
43
7
1
2
5
6
1
7
43
5
2
6
43
7
1
2
5
6
1
7
43
5
2
6
43
7
1
2
5
6
1
7
43
5
2
6
NOT SHOWN
NOT SHOWN
E10 E1J, E1K E1P
CW ROTATION
CCW ROTATION
NOT SHOWN 8910 11 12
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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 seal-
ing 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 (4) with attached parts. Remove spring
(11) and spool (6).
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 cap (19), screw (13) and nut (14). Remove the retainer (7).
1. See Figure 6. Install Avseal plug (9) in cap.
2. Install spool (6) into bore as shown. Install spring (11) over end of spool.
3. Install O-ring (8) on spring retainer (7). Install retainer (7), screw (13), and nut (14)
in plug (4).
4. Install O-ring (15) in bottom of bore as shown. Install O-ring (10) on plug (4).
Install plugs (4) and (12) in body (1). Torque plugs to 60 Nm . Install O-ring (18) in
cap.
5. Turn screw (13) in until spring retainer (7) contacts spring (11). 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 242 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 19,2 +/- 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 hydraulic sealant 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 easi-
ly at all positions of the link (28).
13. Install proportional valve (41) in block. Torque to 27 Nm.
14. Install coil on proportional valve. Torque to 2,2-2,8 Nm max.
15. Assemble all other components into body (16) per Figure 5. Torque the plug (12) to
60 Nm.
16. 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 102 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.
5. Adjust amperage (approx. 125 mA) to give 3,45 bar reading on the proportional
valve gage port. Back out zero screw (24) and adjust screw (9) until output flow is at
ELECTRIC STROKER
ELECTRIC STROKER
DISASSEMBLY
ASSEMBLY
TEST AND ADJUSTMENT
12
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zero stroke position. Lock both adjustments in place.
6. Increase amperage to 290 mA. Pump should go to full stroke. Set max. volume
screw on opposite control cap for full stroke. Gage in proportional valve gage port
should read approximately 14,5 bar.
7. If pump fails to go towards full stroke, or fails to go towards zero stroke, differen-
tial pressure may be improperly adjusted. Re-adjust the screw (13 figure 6) out to go
towards full or in to go towards zero flow. When correct, lock in place and install cap
on differential adjustment.
8. Increase and decrease the amperage between 0 and 290 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 0,7 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 10 l/m from each other.
ELECTRIC STROKER
13
FIGURE 5
ELECTRIC STROKER
FIGURE 6
SERVO CAP
48
36
38
16
46
102 Nm
1
42
41
43
35
37
17
8
9
33 28
5
6
12
39 24 20 23
3
14
46
35
10
11 15 39
719
18 25
34 27 26 21
29 47
102 Nm
44 45 30
44
12 648
13 14
5
19
7
15
1
18
17
2 9 11 10
Loctite
242
Torque
6,8 Nm
Loctite hyd.
sealant
DIFFERENTIAL
ADJUSTMENT
SERVO INLET
3/8 BSPP
CYL. PRESSURE
PORT 1/4 BSPP
TORQUE 30 Nm
TORQUE 35Nm
TORQUE
60 Nm
Servo inlet
3/8 BSPP
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ITEM DESCRIPTION PART NO. QTY.
1 Cap (Figure 6) S22-15619 1
3 Screw 032-91461 1
5 Clevis pin 321-40000 1
6 Spring, Compression 032-92100 1
7Plug, Avseal 447-00026 1
8 Nut, 5/16-24 335-13100 1
9Soc. 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 488-35018 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, M16 032-91822 1
21 Spool 032-91438 1
23 O-Ring,70 S-1 ARP 115 671-00115 1
24 Soc. Setscrew 311-50001 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 1.50 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
37 Screw, HHC, 1/4-20 x 2 1/4 306-40187 3
38 Adapter 032-91507 1
39 O-Ring, 90 S-1 ARP 908 691-00908 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
47 O-ring, 70 S-1 ARP 010 671-00010 1
48 Seal 449-00603 1
ITEM DESCRIPTION PART NO. QTY.
1Cap/Sleeve S22-15620 1
2 Plug 447-01004 1
4 Plug 032-91861 1
5 Plug 449-00599 2
6 Spool 032-59482 1
7 Spring retainer 032-91862 1
8 O-Ring, 90 S-1 ARP 013 691-00013 1
9 Avseal Plug 447-00026 1
10 O-ring, 90 S-1 ARP 910 691-00910 1
11 Spring 032-91863 1
12 Plug, BSPP 1/2 447-01008 1
13 Screw, 5/16 -24 x 1 312-13160 1
14 Nut, 5/16-24 335-13100 1
15 O-ring, 90 S-1 ARP 017 691-00017 1
17 Plug 447-00032 1
18 O-Ring, 70 S-1 ARP 008 671-00008 1
19 Cap 449-00612 1
ELECTRIC STROKER
PARTS LIST FOR FIGURE 5
electric stroker S22-15610
PARTS LIST FOR FIGURE 6
servo cap S22-15619
14
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ELECTRIC STROKER
CONTROL CAP DISASSEMBLY
ASSEMBLY
PARTS LIST FOR FIGURE 7
control cap assembly S22-15613
15
FIGURE 7
CONTROL CAP ASSEMBLY
ITEM DESCRIPTION PART NO. QTY.
1 Control Cap 032-92229 1
2 Plug 449-00599 1
3 O-ring, 70 S-1 ARP 115 671-00115 1
4Screw, M16 -2 x 80 311-50001 1
5 Nut 032-91822 1
6 Plug 488-35018 1
7 O-ring 90 S-1 ARP 908 691-00908 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.
TORQUE
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. Remove maximum volume stop assembly (items 11, 13, 14, 20 and 24).
5. Remove cap assembly (1).
6. See fig. 9. 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 (19).
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 piston (16). Lubricate and install into plug (15). Install O-ring (14) in
bottom of bore as shown. Install O-ring (13) on plug (15). Install plug (15) into cap.
Install screw (3) and nut (4).
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 (26).
6. Install plug (12) and torque to 60 Nm. Install plug (21). Torque to 35 Nm.
7. Carefully install O-ring (30) 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 102 Nm.
9. See figure 8. Install maximum stop screw (24), cover (20) ,O-ring (14) and plug
(11) with O-ring (13).
10. Apply Loctite 242 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 19,2 +/- 0,76 mm.
12. Press dowel (30) into body (16), through the link assembly (28), to 6,35 mm below
surface. Apply Loctite hydraulic sealant®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 plugs (11) to 68 Nm.
15. 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) and torque assembly screws to 102 Nm.
TORQUE LIMITER OVERRIDE
TORQUE LIMITER OVERRIDE
DISASSEMBLY
ASSEMBLY
16
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TORQUE LIMITER OVERRIDE
17
FIGURE 8
TORQUE LIMITER OVERRIDE
P080 QTY.
ITEM DESCRIPTION PART NO. **J **K
1 Cap (Figure 9) S22-15617 1 1
3 Screw 032-91461 1 1
5 Clevis pin 321-40000 1 1
6 Spring, Compression 032-92100 1 1
7Plug, Avseal 447-00026 1 1
8 Screw 032-91445 1 1
9Nut, 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 2 1
13 O-ring, 90 S-1 ARP 908 691-00908 2 1
14 O-ring, 70 S-1 ARP 115 671-00115 1 1
15 Screw, Primary Adjust 032-91446 1 1
16 Body assembly S22-15396 1 1
17 Outer Spring – J Version 032-91440 1 —
Outer Spring – K Version 032-91440 — 1
18 Inner Spring – J Version 032-92240 1 —
Inner Spring – K Version 032-91441 — 1
19 Spring Retainer 032-91819 1 1
20 Nut, M16 032-91822 1 1
21 Spool 032-91438 1 1
23 O-ring, 70 S-1 ARP 118 671-00118 2 2
24 Screw, M16 - 2 x 80 mm 311-50001 1 1
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 1.50 Lg.. 324-20824 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 S22-15615
code K S22-15632
HIGH PRESSURE FLOW
ADJUSTMENT
HIGH FLOW
PRESSURE ADJUSTMENT
TORQUE 68 Nm
LOCTITE HYD. SEALANT
LOCTITE 242
TORQUE 6,8 Nm
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ITEM DESCRIPTION PART NO. QTY.
1 Cap-Sleeve Assembly S22-15618 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 Cap 449-00612 1
18 Spool 032-91820 1
19 Orifice 036-12819 1
21 Plug 447-00032 1
25 Soc. Setscrew 5/16-24 x 1-1/4 312-13180 1
26 Nut, Acorn 036-33474 1
27 Plug 449-00599 1
28 Plug, 1/4 BSPP 447-01004 2
30 O-ring, 70 S-1 ARP 008 671-00008 1
TORQUE LIMITER OVERRIDE
PARTS LIST FOR FIGURE 9,
torque limiter override cap S22-15617
18
FIGURE 9
TORQUE LIMITER OVERRIDE CAP
DIFFERENTIAL ADJUSTMENT
CYLINDER PRESSURE PORT
1/4 BSPP
TORQUE 30 Nm
SYSTEM PRESSURE
1/2 BSPP
TORQUE 60 Nm
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.) When correct, lock in
place and install cap.on differential adjustment.
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 pres-
sure 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
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 20, 21, 22, 23, 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 (19) 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 piston (16). Lubricate and install into plug (15). Install O-ring (14) in
bottom of bore as shown. Install O-ring (13) on plug (15). Install plug (15) into cap.
Install screw (3) and nut (4).
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 60 Nm. Torque plug (31) to 35 Nm.
Torque plug (28) to 30 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 (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. 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 100 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.) When correct, lock
in place and install cap.on differential adjustment.
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.
COMPENSATOR OVERRIDE
COMPENSATOR OVERRIDE
DISASSEMBLY
ASSEMBLY
TEST AND ADJUSTMENT
20
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