Denison Hydraulics Premier Series Operating and installation instructions

DENISON HYDRAULICS
open circuit piston pumps
Premier series P07 & 110 C-mod.
service information
Publ. LT2-00038-2 replaces S1-AM0018 Revised 5/03
Internet http://www.denisonhydraulics.com E-mail: [email protected]
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CONTENTS
2
TITLE PAGE
Port Identification ........................................................................................3
Start up Procedure ......................................................................................7
Trouble shooting charts ..............................................................................8
Disassembly ................................................................................................10
Rework limits ..............................................................................................11
Parts list ......................................................................................................12
Rear drive adapters ....................................................................................16
Conversion ..................................................................................................17
Reassembly ................................................................................................18
Controls ......................................................................................................25
Pressure compensator............................................................................27
Maximum Volume Stop; Handwheel......................................................30
Buck-up cap assembly ..........................................................................31
Torque limiter ..........................................................................................32
Load sensing control ..............................................................................36
Load sensing torque limiter ..................................................................39
Rotary servo ............................................................................................43
Hydraulic stroker ....................................................................................47
Electrohydraulic stroker ........................................................................50
PQ control (pending)..............................................................................54
Control tubing; Control cap ..................................................................58
Compensator override control ..............................................................59
Torque limiter override control ..............................................................61
Testing ........................................................................................................64
Rotary servo test ....................................................................................64
Compensator test ....................................................................................66
Load sensing test....................................................................................67
Hydraulic stroker test ............................................................................68
Electrohydraulic stroker test..................................................................69
Torque limiter and torque limiter override test ....................................70
Load sensing torque limiter test............................................................72
PQ control test (pending) ......................................................................74
Pump test ................................................................................................75
Tools ............................................................................................................76
Characteristics ............................................................................................77
Ordering code ............................................................................................79
Seal kit ..............................................................................P07 S22-15646-0
......................................................................................................P110 S22-15647-0
The shaft seal and all "O" rings necessary for total seal replacement may be obtained
by ordering Seal Kit . These seals are suitable for petroleum base fluids. For fire resis-
tant fluids contact DENISON HYDRAULICS, Inc. or their authorized distributors to
obtain the appropriate seal kit number.
“The product information specifications and descriptions contained in this catalog have been
compiled for the use and convenience of our customers from information furnished by the
manufacturer, and we cannot and do not accept any responsibility for the accuracy or correctness
of any description, calculation, specification or information contained herein. No such description,
calculated, specified or information regarding the products being sold has been made part of the
basis of the bargain nor has same created or amounted to an express warranty that the products
would conform thereto. We are selling the goods and merchandise illustrated and described
in this catalog on an as is basis and disclaim any implied warranty, including any warranty
of merchantability or warranty of fitness for any particular purposes whatsoever, with
respect to the goods and merchandise sold. All manufacturer warranties shall be passed on to
our customers, but we shall not be responsible for special, indirect, incidental or consequential
damages resulting from the use of any of the products or information contained or described in the
catalog.”
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IDENTIFICATION OF PORTS AND ADJUSTMENTS
3
FLUID CONNECTIONS
“XG”
“C2”
with Compensator Override
CCW ROTATION SHOWN
......................DESCRIPTION......................................................................................P07 . . . . . . . . . . . . .P110
PORT A ........INLET ........................................................................................3” SAE CODE 61 . . .3” SAE CODE 61
5/8-11 SCREWS M16-2 SCREWS
PORT B ........SYSTEM ................................................................................1-1/4” SAE CODE 62 1-1/4” SAE CODE 62
1/2-13 SCREWS M14-2 SCREWS
PORT C1 ......OFF-STROKE CYLINDER GAGE......................................................SAE-4 . . . . . . . . . .1/4 BSPP
PORT C2 ......ON-STROKE CYLINDER. GAGE ......................................................SAE-4 . . . . . . . . . .1/4 BSPP
PORT D ........CASE DRAIN ....................................................................................SAE-16 . . . . . . . . . . .1 BSPP
PORT D1 ......CASE DRAIN ....................................................................................SAE-16 . . . . . . . . . . .1 BSPP
PORT DG......DRAIN GAGE, AIR BLEED PORT ....................................................SAE-4 . . . . . . . . . .3/8 BSPP
PORT AG......INLET GAGE ......................................................................................SAE-4 . . . . . . . . . .1/4 BSPP
PORT BG......SYSTEM GAGE..................................................................................SAE-4 . . . . . . . . . .1/4 BSPP
PORT BG1....ALTERNATE SYSTEM GAGE ..........................................................SAE-6 . . . . . . . . . .1/4 BSPP
PORT E ........ELECTROHYDRAULIC STROKER SERVO SUPPLY ......................SAE-4 . . . . . . . . . .1/4 BSPP
PORT H ........HYDRAULIC STROKER SIGNAL......................................................SAE-4 . . . . . . . . . .1/4 BSPP
PORT LS ....LOAD SENSING LINE ......................................................................SAE-4 . . . . . . . . . .1/4 BSPP
PORT V ........COMPENSATOR, TORQUE LIMITER, LOAD SENSING VENT ......SAE-8 . . . . . . . . . .3/8 BSPP
PORT V1 ......SERVO VENT ....................................................................................SAE-4 . . . . . . . . . .1/4 BSPP
PORT X ........SERVO SUPPLY ................................................................................SAE-6 . . . . . . . . . .3/8 BSPP
PORT XG......SERVO GAGE ..................................................................................SAE-10 . . . . . . . . . .1/2 BSPP
“DG”
“AG”
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IDENTIFICATION OF PORTS AND ADJUSTMENTS
4
CLOCKWISE
ROTATION COUNTERCLOCKWISE
ROTATION
High pressure
flow adjustment
High flow
pressure adjustment
High flow
pressure adjustment
High pressure
flow adjustment
"D1" "BG"
"B"
"DG"
"C1"
far side
"V"
Differential
adjustment
"D"
"D1"
"D"
"B"
"BG"
"DG"
PRIMARY CONTROLS
"V"
far side
Compensator
adjustment
Maximum
volume
handwheel
Maximum
volume stop
"C1" Compensator
adjustment
(far side)
Differential
adjustment
Maximum
volume stop
"LS" (P110)
"LS" (P07)
"C1", "C2" COMPENSATOR
"L1", "L2" LOAD SENSING
Maximum volume
handwheel
"J1/K1", "J2/K2" TORQUE LIMITER
"V1/W1", "V2/W2" LOAD SENSING
TORQUE LIMITER
"V1/W1", "V2/W2" LOAD SENSING
TORQUE LIMITER "C1", "C2" COMPENSATOR
"L1", "L2" LOAD SENSING
"LS" (P110)
"LS" (P07)
"LS" (P07)
"LS" (P110)
"J1/K1", "J2/K2" TORQUE LIMITER
"LS" (P07)
"LS" (P110)
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IDENTIFICATION OF PORTS AND ADJUSTMENTS
5
"R" ROTARY SERVO
Maximum stroke
adjustment
"X"
COUNTERCLOCKWISE
ROTATION
"B"
"D"
"D1"
Differential
adjustment
Differential
adjustment
"E"
(P07) "E"
(P110)
Range
adjustment
CLOCKWISE
ROTATION
Range
adjustment
Range
adjustment
"E"
(P07) "E"
(P110)
Maximum stroke
adjustment
"C2"
"D"
"D1"
Secondary
control
"B"
"C2"
far side
Secondary
control
"V1"
far side
"BG"
"DG"
"V1"
"BG"
"DG"
Range
adjustment
(P07)
"H"
(P110)
(P07)
"H"
(P110)
"X"
"R" ROTARY SERVO
"H" HYDRAULIC STROKER
"E" ELECTROHYDRAULIC STROKER
"E" ELECTROHYDRAULIC STROKER
"H" HYDRAULIC STROKER
PRIMARY CONTROLS
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IDENTIFICATION OF PORTS AND ADJUSTMENTS
6
CLOCKWISE
ROTATION COUNTERCLOCKWISE
ROTATION
"*1P"
COMPENSATOR OVERRIDE WITH
MAXIMUM VOLUME STOP
Maximum
volume stop High pressure
flow adjustment
High flow
pressure adjustment
"*1J", "*1K"
TORQUE LIMITER OVERRIDE WITH
MAXIMUM VOLUME STOP
"*10"
CONTROL CAP WITH
MAXIMUM VOLUME STOP
"C1"
far side
High flow
pressure adjustment
High pressure
flow adjustment
Maximum
volume stop
"D1" "BG"
"B"
"DG"
"C2"
far side
"*1J", "*1K"
TORQUE LIMITER OVERRIDE WITH
MAXIMUM VOLUME STOP
"C1"
far side
"V" Differential
adjustment
Compensator adjustment
(far side)
"*1P"
COMPENSATOR OVERRIDE WITH
MAXIMUM VOLUME STOP
Primary
control
Differential
adjustment
"D"
"V1"
(far side)
"*10"
CONTROL CAP WITH
MAXIMUM VOLUME STOP
Compensator
adjustment
"V"
far side
"C1"
"D1"
"D"
"B"
Differential
adjustment
Primary
control
"BG"
"DG"
Minimum
volume stop
Minimum
volume stop
"X"
"X"
SECONDARY CONTROLS
Differential
adjustment
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START UP
7
START UP PROCEDURE FOR NEW INSTALLATION
• Read and understand the instruction manual. Identify components and their function.
• Visually inspect components and lines for possible damage.
• Check reservoir for cleanliness. Drain and clean as required
• Check fluid level and fill as required with filtered fluid at least as clean as that recommended. Fill pump case with
clean oil prior to starting. If pump is mounted vertically with shaft up, bleed air from case by removing plug from port
“DG” till fluid runs clear.
• Check alignment of drive.
• Check oil cooler and activate it, if included in circuit. Check fluid temperature
• Reduce pressure settings of compensator and relief valve. Make sure accurate pressure readings can be made at
appropriate places.
• If solenoids are in system, check for actuation.
• Start pump drive. Observe for correct shaft rotation. Make sure pump fills properly.
• Bleed system of air. Recheck fluid level.
• Cycle unloaded machine at low pressure and observe actuation (at low speed, if possible).
• Increase pressure settings gradually in steps. Check for leaks in all lines, especially in pump inlet lines.
• Make correct pressure adjustments.
• Gradually increase speed. Be alert for trouble as indicated by changes in sounds, system shocks and air in fluid.
• Equipment is operational.
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TROUBLESHOOTING
8
Component problems and circuit problems are often interrelated. An improper circuit may operate with apparent success but will
cause failure of a particular component within it. The component failure is the effect, not the cause of the problem. This general
guide is offered to help in locating and eliminating the cause of problems by studying their effects.
Effect of Trouble Possible Cause Fault Which Needs Remedy
pump
noisy air in system leak in suction line.
low fluid level.
turbulent fluid.
return lines above fluid level.
gas leak from accumulator.
excessive pressure drop in the inlet line from a
pressurized reservoir.
suction line strainer acting as air trap.
cavitation in rotating group. fluid too cold, too viscous, or too heavy.
shaft speed too high.
suction line strainer too small, or strainer too dirty.
operating altitude too high.
boost pressure too low.
inlet flow too small for dynamic conditions.
misaligned shaft. faulty installation.
distortion in mounting.
axial interference.
faulty coupling.
excessive overhung loads.
mechanical fault in pump. piston and shoe looseness or failure.
bearing failure.
incorrect port plate selection or index.
eroded or worn parts in the displacement control.
erosion on barrel ports and port plate. air in fluid. see noisy pump above.
cavitation. see noisy pump above.
high wear in pump. excessive loads. reduce pressure settings.
reduce speeds.
contaminant particles in fluid. improper filter maintenance.
filters too coarse.
introduction of dirty fluid to system.
reservoir openings.
improper reservoir breather.
improper line replacement.
Improper fluid. fluid too thin or thick for operating temperature range.
breakdown of fluid with time/temperature/shearing
effects.
incorrect additives in new fluid.
destruction of additive effectiveness with chemical aging
improper repair. incorrect parts, procedures, dimensions, finishes.
unwanted water in fluid. condensation.
faulty breather/strainer.
heat exchanger leakage.
faulty clean-up practice.
water in makeup fluid.
pressure shocks. cogging load. mechanical considerations.
worn relief valve. needed repairs.
worn compensator. needed repairs.
slow response in check valves. replace or relocate.
excessive decompression improve decompression control.
energy rates.
excessive line capacitance. reduce line size or lengths.
(line volume, line stretch, eliminate hose.
accumulator effects).
barrel blow-off. re-check pump holddown,rotating group, drain pressure.
heating of fluid. excessive pump leakage. recheck case drain flow and repair as required.
fluid too thin.
improper assembly, port timing.
relief valve. set too low (compared to load or to compensator).
instability caused by back pressure, worn parts.
compensator. set too high (compared to relief).
worn parts.
pump too large for fluid needs. select smaller pump displacement.
heat exchanger. water turned off, too hot or too little flow.
fan clogged or restricted.
efficiency reduced by mud or scale deposits.
intermittent hydraulic fluid flow.
reservoir. too little fluid.
improper baffles.
insulating air blanket that prevents heat rejection.
heat pickup from adjacent equipment..
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TROUBLESHOOTING
9
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 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
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
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DISASSEMBLY INSTRUCTIONS
10
Figure 1
Exploded view of pump
with
pressure compensator control
Figure 2
Volume indicator assembly
item 52
thread
locking
com-
pound
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REWORK LIMITS OF WEAR PARTS
maximum rework minimum dimension
item from original dimension after rework
wear plate.005", 0,127 mm.184", 4.674 mm
piston shoe face(pocket) * .4175", 10,605 mm
*shoe face pocket depth must be .004”, 0,10 mm minimum
WEAR PLATE
The wear plate finish must be 10 µin., 0,25 µm minimum, flat within .0005", 0,0127 mm and parallel to the backside
within .001", 0,0254 mm total indicator reading.
PISTON SHOE
The piston shoe wear face finish must be 45 µin., 1,143 µm min, and must be lapped in a set with the retainer plate. All
shoe sole thicknesses to be within .001", 0,0254 mm after lapping. The maximum permissible shoe and piston axial
looseness is .010", 0,254 mm.
Disassembly
Disassemble only as far as necessary to replace or repair worn parts.
If the pump has a rear drive, the mounting adapter and coupling must be removed prior to pump disassembly Refer to
figure 3 page 16.
Clean outside surface of the pump before disassembly. Disassembly area should be clean. A suitable surface should
be used capable of supporting the pump weight of 177 lbs, 80,3 Kg.
Refer to illustration, see figure 1 and 2
1. Remove plug (49) and drain oil from pump. Position pump with shaft up.
2. Wind maximum volume screw CW (ref item (50), item 1 page 27) so that piston (44) bottoms out. This positions the
cam at approximately zero displacement allowing removal of the drive shaft.
3. Remove socket head cap screws (9). If disassembling PQ Control version, remove tubing and pass thru fitting (56).
4. Remove cradle assembly (6) from the housing. The threaded hole in end of the shaft is provided for lifting
this assembly. Threaded hole is 3/8-16 for P07, M10 for ISO and M12 for DIN shaft.
5. Remove snap ring (4).
6. Remove screws (47) to remove cam bearing (42).
7. Remove shaft (1), bearing, and seal retainer. Support flat face of the rocker cradle and press end of shaft opposite
the bearing end.
8. Remove the shaft seal (1c) from the retainer (1e) if necessary.
9. Remove retaining ring (20).
10.Press bearing off shaft if necessary. Press against bearing inner race.
11.If pump contains a volume indicator assembly (52): Refer to. Figure 2: Remove indicator pointer (2), retaining ring
(9) and pivot nut (1) from pump housing. Remove pivot shaft and fork assembly (3) and (4) through the hole.
11.Remove two screws (34), two washers (25), clearance bearing (24), and two washers (23) from retainer (28).
12.Wind maximum volume screw CCW until piston (44) bottoms out.
13.Remove control cap (50) and control cap (31). (Refer to controls section for control disassembly).
14.The piston must be moved outward (away from pump center) to remove cam assembly.
15.Lift cam assembly (10) from pump. (Link (43), pistons and shoes and retainer plate(17), wear plate (22), and hold-
down (45 and 46) are part of the cam assembly.)
16.Remove slide link (43), retaining ring (45), thrust washer (46), pistons, shoes & retainer assembly (17) and wear
plate (22). The pins for the slide link and for the indicator have been pressed into the rocker cam and should not be
removed.
17.Remove two screws (26), and two retainers (28).
18.Remove Belleville washers (18) and barrel stop (19).
19.Attach tool (T-1) (pg. 76) to barrel assembly (14-1). (Two M6 screws are required.) Lift barrel from port plate and
housing.
20.The inner race of bearing (11) has a light press fit with barrel. Do not remove the inner race unless bearing needs
to be replaced. If replacement is necessary, remove seven socket head cap screws (12). Replace with 5/16-18
UNC x 6 1/2 in. long soc hd cap screws. Rest assembly on the extended screws. Press barrel from inner race.
Care must be taken to avoid damage to barrel face.
21.Remove port plate ref. see item (14), and alignment pin (16), from port block.
The barrel bearing outer race (11) should only be removed from housing if worn, damaged or closer inspection is
needed. A bearing puller should be used for removal.
DISASSEMBLY INSTRUCTIONS
11
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PUMP PARTS LISTS
12
Ref. Figure 1
Exploded view of pump
with
pressure compensator control
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PUMP PARTS LISTS
13
item description part no. part no. qty.
P07-SAE P110-ISO
1 shaft assembly 1
keyed, no rear drive S22-15337 S22-15598
a (shaft) 032-91829 032-92197
b (bearing) 230-82216 230-82216
c (seal) 620-82080 230-82080
d (key) 033-71514 032-91429
e (seal retainer) 032-91835 032-91835
keyed, with rear drive S22-16027 S22-16028
a (shaft) 032-92525 032-92526
b (bearing) 230-82216 230-82216
c (seal) 620-82080 230-82080
d (key) 033-71514 032-91429
e (seal retainer) 032-91835 032-91835
splined, no rear drive S22-15338 S22-15599
a (shaft) 032-91828 032-92198
b (bearing) 230-82216 230-82216
c (seal) 620-82080 230-82080
e (seal retainer) 032-91835 032-91835
splined, with rear drive S22-16025 S22-16026
a (shaft) 032-92524 032-92527
b (bearing) 230-82216 230-82216
c (seal) 620-82080 230-82080
e (seal retainer) 032-91835 032-91835
P110-DIN
keyed, no rear drive S22-15673
a (shaft) 032-92255
b (bearing) 230-82216
c (seal) 620-82080
d (key) 032-92246
e (seal retainer) 032-91835
keyed, with rear drive S22-16030
a (shaft) 032-92529
b (bearing) 230-82216
c (seal) 620-82080
d (key) 032-92246
e (seal retainer) 032-91835
splined, no rear drive S22-15602
a (shaft) 032-92212
b (bearing) 230-82216
c (seal) 620-82080
e (seal retainer) 032-91835
splined, with rear drive S22-16029
a (shaft) 032-92528
b (bearing) 230-82216
c (seal) 620-82080
e (seal retainer) 032-91835
4 retainer 356-65086 356-65086 1
5 O-ring, 70 S-1 ARP 155 671-00155 671-00155 1
6 cradle 032-92446 032-92477 1
7 housing, no rear drive 032-92473 032-92579 1
housing, with rear drive 032-92481 032-92580
8 O-ring, 70 S-1 ARP 263 671-00263 671-00263 1
9 screw, SHC 361-11213 361-11213 14
10 cam assembly S22-15903 S22-15903 1
11 bearing 032-92449 032-92449 1
12 screw, SHC 361-10234 361-10234 7
14barrel & port plate assembly CWS22-16145 S22-16145 1
barrel & port plate assembly CCWS22-16146 S22-16146
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item description part no. qty.
1 Pivot nut 032-92491 1
2 Indicator 033-70624 1
3 fork 032-92653 1
4 pivot shaft 032-92492 1
5 glyd ring 679-00030 1
6 Soc. setscrew, 10-32 x 3/16 312-09030 1
7 O-ring, 70 S-1 ARP 114 671-00114 1
8 O-ring, 90 S-1 ARP 914 691-00914 1
9 Retaining ring 356-65070 1
PARTS LIST FOR INDICATOR ASSEMBLY
Ref. Figure 1
Exploded view of pump
with
pressure compensator control
Ref. figure 2
Indicator Assembly (52)
S22-16262
PUMP PARTS LISTS
14
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item description part no. part no. qty.
P07-SAE P110-ISO
16 dowel pin 324-21610 324-21610 1
17 pistons, shoes,retainer assembly S22-16039 S22-16039 1
(17-1) retainer plate (1 req’d) 032-92453 032-92453
(17-2) pistons and shoes (7 req’d) S22-16031 S22-16031
18 Belleville washer 032-91827 032-91827 2
19 stop 032-91824 032-91824 1
20 retaining ring 032-91825 032-91825 1
22 wear plate 032-92452 032-92452 1
23 lockwasher 348-10016 348-10016 2
24 bearing 032-91602 032-91602 1
25 washer 345-10012 345-10012 2
26 screw, SHC 361-08200 361-08200 4
27 O-ring, 90 S-1 ARP 013 691-00013 691-00013 6
28 cam/bearing retainer 032-92470 032-92470 2
30 O-ring, 70 S-1 ARP151 671-00151 671-00151 2
31 off stroke control side (see page 17) 1
buck-up cap (comp, torque limiter, load sensing) S22-15447 S22-15447
electric stroker S22-16204 S22-16203
hydraulic stroker S22-16202 S22-16201
rotary servo S22-16200 S22-16199
32 plug 488-35061 447-00032 2
33 O-ring, 90 S-1 ARP 904 691-00904 none 3
34 screw, SHC 361-08704 361-08704 2
35 Screw, HHC, M12 x 1,75 x 55 mm lg. 363-12205 363-12205 *
Screw, HHC, M12 x 1,75 x 75 mm lg.(E,H,R,J,K) 363-12220 363-12220 *
Screw, HHC, M12 x 1,75 x 85 mm lg. (L) 363-12233 363-12233 *
39 ring (qty. 1 for servo, electric & hydraulic stroker) 032-91816 032-91816 2
ring (servo, electric & hydraulic stroker) 032-91811 032-91811 1
40 O-ring, 90 S-1 ARP 906 691-00906 none 2
41 plug 488-35041 447-00032 2
42 bearing 032-92454 032-92454 2
43 slide link 032-91823 032-91823 1
44 control piston (compensator, torque limiter) 032-91836 032-91836 1
control piston (servo, electric & hydraulic stroker) 032-91848 032-91848
45 bearing 032-91830 032-91830 1
46 retainer, white, .062", 1,57 mm thick 032-91853 032-91853 1
retainer, red, .064”, 1,63 mm thick 033-91854 033-91854
retainer, green, .067”, 1,70 mm thick 033-91855 033-91855
retainer, yellow, .069”, 1,75 m thick 033-91856 033-91856
retainer, blue, .071", 1,80 mm thick 033-91857 033-91857
47 screw, FHSHCS 316-50001 316-50001 2
48 O-ring, 90 S-1 ARP 916 691-00916 none 1
49 plug 488-35024 447-01016 1
50 on stroke control side (see page 17) 1
compensator (C1) S22-15394 S22-15623
compensator (C2) S22-15626 S22-15633
low torque limiter (J1) S22-15401 S22-15624
low torque limiter (J2) S22-15627 S22-15634
high torque limiter (K1) S22-15629 S22-15631
high torque limiter (K2) S22-15635 S22-15636
load sensing (L1) S22-15402 S22-15625
load sensing (L2) S22-15628 S22-15637
low torque limiter w/load sensing (V1) S22-16186 S22-16188
low torque limiter w/load sensing (V2) S22-16195 S22-16196
high torque limiter w/load sensing (W1) S22-16187 S22-16189
high torque limiter w/load sensing (W2) S22-16197 S22-16198
compensator override S22-16205 S22-16206
low torque limiter override S22-16207 S22-16208
high torque limiter override S22-16209 S22-16210
max. volume screw, servo S22-15325 S22-15613
51 shipping plug 449-00019 449-00613
52 plug 488-35030 488-35030 1
indicator assembly (see figure 2) S22-16262 S22-16262
53 O-ring, 90 S-1 ARP 914 691-00914 691-00914 1
PUMP PARTS LISTS
15
*qty and size depends on control (31) and (50). see controls section, starting pg 25
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REAR DRIVE PARTS LISTS
16
SAE REAR DRIVES
code A G B Q C N D
flange SAE 82-2 SAE 82-2 SAE101-2/4 SAE101-2/4 SAE127-2/4 SAE127-2/4 SAE152-4
coupling 16-4 22-4 22-4 25-4 32-4 38-4 44-4
item part qty (“A”) (modified “A”) (“B”) (“B-B”) (“C”) (“C-C”) (“D”)
1 adapter 1 032-91900 032-91900 032-91309 032-91309 032-91308 032-91649 032-91282
2 coupling 1 032-91901 032-92377 032-91361 032-91362 032-91363 032-91648 032-91634
3 screw 4 361-16304--8 361-16304-8 361-16304-8 361-16304-8 361-16304-8 361-16304--8 361-16304--8
4 O-ring 1 671-00152 671-00152 671-00155 671-00155 671-00159 671-00159 671-00163
5 O-ring 1 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159
6 washer 4 350-10109-
assembly S22-15372 S22-15809 S22-12867 S22-12868 S22-12869 S22-12920 S22-12870
note: code M item (1) blanking plate part no. 032-91468 item (3) blanking plate screws 363-16210-8
ISO REAR DRIVES
code Z Y X T U L
flange ISO 100 ISO 125 ISO 160 ISO 180 ISO 180 ISO 180
coupling ISO K25N ISO K32N ISO K40N ISO K40N ISO K50N DIN 40-18
item part qty
1 adapter 1 032-91383 032-91384 032-91385 032-92162 032-92162 032-92162
2 coupling 1 032-91391 032-91390 032-91389 032-91389 032-91388 032-92345
3 screw 4 361-16304-8 361-16304-8 361-16304-8 361-16304-8 361-16304-8 361-16304-8
4 O-ring 1 671-00155 671-00159 671-00164 671-00167 671-00167 671-00167
5 O-ring 1 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159
6 washer 4 350-10109 350-10109 350-10109 350-10109
assembly S22-12872 S22-12873 S22-12874 S22-15740 S22-15570 S22-15933
Figure 3
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CONVERSION
17
E, H, R CONTROLS
LOCATION (item 31 Fig. 1)
E, H, R CONTROLS
LOCATION (item 31 Fig. 1)
Figure 5
CONTROL ORIENTATION VERSUS PUMP ROTATION
ROTATION CONVERSION
The following parts and assembly are required for changing shaft rotation:
• A different barrel and port plate assembly is required. The barrel and port plate are matched assemblies, and should
not be ordered separately. The reference part numbers are:
CW - Barrel and Port Plate AssemblyS22- 16145
CCW - Barrel and Port Plate AssemblyS22- 16146
• The control piston must be reversed to position it correctly to the control caps. See step 9 pg. 20)
• The control caps location are reversed. see illustrations below.
C, J, K, L, V, W CONTROLS
LOCATION (item 50 Fig. 1) Figure 4
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PUMP REASSEMBLY INSTRUCTIONS
18
SHAFT SEAL REPLACEMENT
See illustration Remove worn or damaged seal from retainer. Clean gasket sealant
from retainer.
Install new seal by applying gasket sealant to retainer and pressing seal in retainer.
SEAL KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P07 S22-15646-0
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P110 S22-15647-0
The shaft seal and all "O" rings necessary for total seal replacement may be obtained
by ordering the Seal Kit . These seals are suitable for petroleum base fluids. For fire resistant fluids contact DENISON
HYDRAULICS, Inc. or their authorized distributors to obtain the appropriate
seal kit number.
SHAFT ASSEMBLIES (see parts list, item (1) on page 13)
The following assemblies include shaft, key when applicable, bearing and seal:
P07-SAE # P110-ISO #
Keyed, no rear drive assembly S22-15337 S22-15598
Keyed, with rear drive assembly S22-16027 S22-16028
Splined, no rear drive assembly S22-15338 S22-15599
Splined, with rear drive assembly S22-16025 S22-16026
P110-DIN #
Keyed, no rear drive assembly S22-15673
Keyed, with rear drive assembly S22-16030
Splined, no rear drive assembly S22-15602
Splined, with rear drive assembly S22-16029
PRE-ASSEMBLY
Depending on the repairs, many steps in this section may not be applicable.
The assembly area should be clean and the environment such that foreign matter will not be introduced to the pump
during assembly. All parts must be absolutely clean and free from rust, contamination, lint, or any other foreign matter.
Critical surfaces must be free of dings or scratches. All "O" rings and seals must be clean and carefully examined for
cuts or other damage before installation.
During assembly, occasional reference will be made to the use of lubricating oil for proper assembly. It is important
that any oil used be compatible with the seals and fluid to be used in operation. Compatibility is also necessary for
grease which should be used on all "O" rings to ensure proper assembly without damage.
THREAD LOCKING AND SEALANT
Several screws require a thread locking compound for locking in position. When thread locking compound is required
use Loctite® #242 or equivalent. Where hydraulic sealant is specified, use Loctite® Hydraulic Sealant or equivalent.
Where gasket sealant is specified, use Loctite® Master Gasket or equivalent.
ASSEMBLY
Refer to illustration, see figure 1. See page 26 for tightening torque on plugs
1. Place the port block end of the housing (7) on a suitable surface capable of supporting the pump weight of 177 lbs,
80,3 Kgs.
2. Install plugs (41) with "O" rings into port block. Install plugs (32) with "O" rings into port block.
3. Install pin (16) in port block. Position port plate (14) on port block and over pin. To view correct port plate for shaft
rotation specified. See illustration, below
Port Plate for CW Shaft Rotation
(Ref. Barrel and Port Plate Assembly S22-16145)
Port Plate for CCW Shaft Rotation
(Ref. Barrel and Port Plate Assembly S22-16146)
SLOT FOR PORT
BLOCK LOCATING PIN
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Ref. Figure 1
Exploded view of pump
with
pressure compensator control
PUMP REASSEMBLY INSTRUCTIONS
19
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PUMP REASSEMBLY INSTRUCTIONS
20
4. Press bearing outer race (11) into housing (7).
BARREL AND INNER RACE ASSEMBLY
5. Thread seven M8-1,25 studs into bearing inner race. Lower barrel (14)
over studs and seat. If the inner race is heated to 1500F, 650C, barrel will
slide into position without force. If race is not heated, longer screws (12)
can be used to draw the race and barrel together. Insert screws (12) and
torque to 30 lbs ft., 40 Nm. See illustration
6. Apply oil to face of port plate and inner bearing race. Attach tool T-1 to
barrel with two M6 screws. Carefully lower barrel assembly into housing
engaging inner race into rollers of outer bearing race, barrel may then be
lowered until it has seated on port plate.
7. Insert two "O" rings (27) into each retainer (28). Apply thread locking
compound to two screws (26) and secure retainer to housing. Torque to 84 lbs-in., 9,5 Nm.
8. Apply thread locking compound to two screws (26) and assemble the other retainer on opposite side of housing.
Torque to 84 lbs-in., 9,5 Nm.
9. Assemble the two piston rings (39) on control piston (44). Insert control piston (44) into housing bore that is used
with the control caps. For CW shaft rotation, the long end of the piston must be positioned to the right. (Ref. fig.1)
For CCW rotation, the long end of the piston is to the left.
10. Position Belleville washers (18) on barrel, See illustration. To insure proper pump opera-
tion and correct barrel holddown force they must be assembled exactly as shown. Place
barrel stop (19) on Belleville washers and center the washers and stop on barrel.
CAM ASSEMBLY
11. Set cam assembly (10) on suitable surface protecting cam surfaces from damage during
assembly. See illustration
12. Place wear plate (22) on cam.
13. Position pistons-shoes-retainer assembly (17) over center post and against wear plate.
14. Install thrust washer (45) over center post.
15. Six different retainers (46) are available for setting the shoe holddown. Each retainer is
marked: white dot .062", 1,57 mm thick, red dot .064", 1,63 mm thick, green dot .067",
1,70 mm thick, yellow dot .069", 1,75 mm thick, and blue dot .071", 1,80 mm thick. Install the thickest retainer
with the dot side up, that will fit in the groove on the center post and allow a clearance of .003"-.005",
0,076-0,127 mm between the shoe and wear plate. A .003", 0,076 mm feeler gage must go completely under
any shoe, and a .005”, 0,127 mm feeler gage must not go under any
shoe while holding a piston and lifting tightly against the shoe retainer.
The piston and shoe assembly must be free to rotate easily by hand.
Rotate 360oto confirm there is no binding and that each shoe is free in
the retainer plate. Oil the assembly thoroughly.
16. Install slide link (43) on rocker cam pin as shown.
17. Oil barrel bores before installing cam assembly. The piston must be
moved outward (away from pump center) so that clearance is provided for
installing the rocker cam assembly. Lower cam assembly into the housing
with the slide link positioned so it will engage into the control piston (44).
The seven pistons (17) must first be engaged into the barrel bores.
Next the slide link (43) must engage into the control piston (44). Continue
lowering rocker cam assembly until it is seated on cam/bearing retain-
ers(28).
18. Apply thread locking compound to two screws (34) and assemble clear-
ance-bearing (24) to cam-bearing retainer (28) using the screws (34), two
washers (25) and two washers (23). Move rocker cam to the right until it
is against stop. Set clearance between clearance bearing (24) and cam at
.006", 0,152 mm. Torque screws to 6 lbs-ft., 8,1 Nm maintaining the .006",
0,152 mm clearance.
19.Adjust piston (44) toward the off stroke control side (31). This will place the cam at
approximately zero displacement and provide clearance for the shaft installation.
18
19
.005/.003” (,127/,076 mm)
SHOE CLEARANCE
17
46
45
22
10
43
24
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