Denison Hydraulics Premier Series Operating and installation instructions

DENISON HYDRAULICS
Premier Series
open circuit pump controls
P16 B-mod, P09 A-mod
service information
Publ. S1-AM026-A replaces S1-AM026
Internet: http://www.denisonhydraulics.com E-mail: [e-mail]
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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--------------------------------------------------------------------------------
fluid connections-------------------------------------------------------------------------------------
installation drawings--------------------------------------------------------------------------------
controls key sheet------------------------------------------------------------------------------------
technical data conversions-------------------------------------------------------------------------
Pump seal kit (includes all controls) P09, S22-15084 P16, S22-12830 See key sheet
pg. 48 for information
PAGE
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2
Note: Changes too extensive to identify separately
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3
TYPICAL CHARACTERISTICS
FLUID CONNECTIONS
CHARACTERISTICS
Specification
• compensator response off-stroke
on-stroke
(per SAE J745 Apr. 87 at 5000 psi, 345 bar)
• compensator adjustment
• minimum compensating pressure
(comp, load sensing, torque limiter)
• minimum comp. override pressure at 1200 psi,
83 bar servo pr. (servo, elec. & hyd. str. )
• torque limiter adjustment range code J
code K
• typ. servo & stroker response @ 1200 psi, 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 current (24V) 0 disp.
full disp.
• electric stroker control current (12V) 0 disp.
full disp.
pulse width modulation frequency:
mating connector: Din 43650 type AF
part no. 167-10008-8 (provided)
• electric stroker nominal coil resistance (24v.)
• electric stroker nominal coil resistance (12v.)
• handwheel turns, full to zero stroke
• torque to turn handwheel @ 1000 psi, 70 bar
• torque to turn handwheel @ 7250 psi, 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)
* on-stroke response for compensator override is
determined by servo/stroker response
**add case pressure
Term
sec.
sec.
psi/turn
bar/turn
psi
bar
psi
bar
in-lbs
Nm
in-lbs
Nm
sec.
in3/min.
l/min.
in3/min.
l/min
psi
bar
degrees
in3/rev/deg.
cc/rev/deg.
in-lbs
Nm
psi
bar
psi
bar
mA
mA
mA
mA
Hz
ohms
ohms
turns
in-lbs
Nm
in-lbs
Nm
SAE
SAE
SAE
SAE
SAE
SAE
P16
0.100*
0,150*
2000
138
200**
13,6**
1350**
93,1**
2500-6000
282 - 706
over 6000
over 706
<0.7
693
11,4
924
15,2
1500
103
80
0.20
3,25
20
2,3
50
3,45
275
19
125
335
250
670
100-150
41
10
10.2
150
17
350
40
-4
-4
-4
-4
-8
-6
P09
0.070*
0.140*
2000
138
200**
13,6**
1250**
86**
1400-2200
160 - 250
over 2200
over 250
<0.7
693
11.,4
924
15,2
1500
103
64
0.134
2,20
20
2,3
50
3,45
230
16
125
315
250
630
100-150
41
10
8.1
125
15
275
32
-4
-4
-4
-4
-8
-6
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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 pres-
sure is applied to the input port of the valve, and to one end of the spool. A small ori-
fice feeds this pressure to the other end of the spool, and limits pilot flow to approxi-
mately 115 in3/min., 1,9 L/m. 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 pston 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 200 psi, 13,6 bar difference, the spool shifts toward the
spring, re-directing the control piston port to pressure. This pressure 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 200 psi, 13,6 bar above the controlled
pressure on the spring side. The spring end of this three-way spool may also be con-
nected 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 200 psi, 13,6 bar above the load pressure. The valve between
the pump and the load meters the flow, The pump provides the flow to develop 200
psi, 13,6 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 115 in3/rev., 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 300
psi, 20,7 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=C. As pressure increases, displacement must reduce, and vice versa. A
linkage to the pump control piston 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, which is ported
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 correspond-
ing position for the control piston. The position of the pin is determined by the pres-
sure, the spring rate, and the initial adjustment on the springs. As pressure increases,
pump stroke must reduce.
At low pressure, high flow, 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=C 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, this end of 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 piston 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 50 psi, 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
INTRODUCTION
GENERAL
DESCRIPTION OF OPERATION
PRESSURE COMPENSATOR
COMPENSATOR WITH LOAD
SENSING CONFIGURATION
LOAD SENSING CONTROL
TORQUE LIMITER
ROTARY SERVO CONTROL
HYDRAULIC STROKER
4
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pump to stroke in proportion to control pressure. Full stroke is achieved at 230 psi, 16
bar, (P09), and 275 psi, 19 bar (P16).
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 315 mA, (P09) and 335 mA, (P16), the pump will be at full stroke.
An override pressure compensator or a torque limiter control mounts on the smaller
diameter of the control piston, opposite the servo, hydraulic or electric stroker. In the
normal position, the spool in the override control connects this piston to servo pres-
sure, allowing control by the stroker. When system pressure or torque exceed the
override setting, this spool connects system pressure to the smaller diameter control
piston, to override the command and reduce stroke according to the compensator or
torque limiter setting
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
CCW ROTATION
CW ROTATION
C10 C20
PRESSURE COMPENSATOR
parts list P09 P16 QTY.
ITEM DESCRIPTION PART NO. PART NO. C10 C20
1 Max. Vol. Stop (Fig. 1) S22-12983 S22-12983 1 —
Max Vol. Handwheel (Fig. 2) S22-12915 S22-12915 — 1
2 Compensator Control (Fig. 3) S22-15311 S22-15311 1 1
3 Buck Up Cap (Fig. 4) S22-15653 S22-12970 1 1
4 Screw-H.H.C.,M12 x 60 mm 363-12210 363-12210 8 6
5 Screw-H.H.C., M12 x 80 mm 363-12225 363-12225 — 2
6 Control Piston 032-91585 032-91443 1 1
7 O-Ring, 90 S-1 ARP 013 691-00013 691-00013 2 2
8 O-Ring, 70 S-1 ARP 152 671-00152 671-00152 2 2
9 Piston Ring 032-91261 032-91261 2 2
ITEMS 6 7 8 9
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 75 lbs.•ft., 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
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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 (12) to 75
lb.•ft., 102 Nm. Torque plug (21) to 46 lb.•ft., 62 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 75 lbs.•ft., 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 500 PSI, 35 bar. If testing on application, apply
a load to pump.
5. Start prime mover. Pump should be at full displacement at 500 PSI, 35 bar.
6. Increase system relief valve until compensator de-strokes pump to zero displace-
ment. Set compensator to 1500 PSI, 103 bar.
7. Adjust compensator differential spool pressure to 200 PSI, 13,8 bar. This is accom-
plished by adjusting the differential screw until the difference in pressure readings
between the system pressure and compensator vent gages installed in the compensator
cap is 200 PSI, 13,8 bar. (It may be necessary to change differential to gain stability. Use
caution when exceeding 250 PSI, 17 bar to avoid spring going solid, preventing compen-
sator action.)
8. Set the compensator to 3000 PSI, 207 bar, 6000 PSI, 414 bar, and 7250 PSI, 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 150 PSI, 10,3 bar from the com-
pensator setting. The control should be steady and stable at all conditions.
10. Reduce pressure to 150 PSI, 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 6000 PSI, 414 Bar if not oth-
erwise 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 S22-15311 ITEM DESCRIPTION PART NO. QTY.
1 Cap-Sleeve Assembly S22-12880 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
12 Plug, SAE-10 488-35055 1
13 O-Ring, 90 S-1 ARP 910 691-00910 2
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
21 Plug, SAE -8 488-35018 1
22 O-Ring, 90 S-1 ARP 908 691-00908 1
25 Soc.Setscrew 5/16-24 x 1-1/4 312-13180 1
26 Acorn Nut 036-33474 1
28 Plug, SAE -4 488-35061 1
29 O-Ring, 90 S-1 ARP 904 691-00904 1
PRESSURE COMPENSATOR
9
FIGURE 3
COMPENSATOR
21
19
12
13
25
26
4
5
6
7
9
8
10
15
17
4316
6
13 11 21
22 18 14 28
29
SYSTEM PRESS.
SAE-10 ST.THD
TORQUE 75 FT-LB,
102 Nm
PORT
C1, SAE-4
ST.THD
TORQUE
11 FT-LB,
15 Nm
VENT CONN.“V”
SAE-8 ST.THD.
TORQUE 46 FT-LB,
62 Nm
DIFFERENTIAL
ADJUSTMENT
COMPENSATOR
ADJUSTMENT
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FIGURE 4
BUCK-UP CAP
BUCK-UP CAP DISASSEMBLY
ASSEMBLY
PARTS LIST FOR FIGURE 4
P09 buck-up cap S22-15653
P16 buck-up cap S22-12970
PRESSURE COMPENSATOR
10
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(s) (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 piston
(1), O-ring (5) and plug (6) into cap.
2. Install O-rings on interface between cap and pump control pad. Install spring (2a)
and spring (2b) (in P09 only) 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 75 ft-lb, 102 Nm. Torque plug (6) to value indicated on
fig. 4.
P09 P16
ITEM DESCRIPTION PART NO. QTY. PART NO. QTY.
1 Piston 324-26448 1 324-24048 1
2a Spring 032-92244 1 032-91273 1
2b Spring (P09 only) 032-92316 1
3 Sleeve 032-92247 1 032-91344 1
4 Control Cap 032-92248 1 032-91266 1
5 O-Ring 691-00920 1 691-00916 1
6 Plug 488-35019 1 488-35024 1
7 Avseal Plug 447-00026 1 447-00026 1
1
2a
3
5
7
64
2b
P16
P09
TORQUE
225 LB-FT
305 Nm
TORQUE
140 LB-FT
190 Nm
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7
4
1
9
3
3 5 6
8
2
NOT SHOWN
8
2
7
4
1
9
3
3 5 6
11
ELECTRIC STROKER
ELECTRIC STROKER
parts list P09 P16 QUANTITY
ITEM DESCRIPTION PART NO. PART NO. E10 E1J E1K E1P
1 Electric Stroker (Fig. 5) S22-15305 S22-15305 1 1 1 1
2 Control Cap (Fig. 7) S22-15256 S22-15256 1 — — —
Low Torque Override (Fig. 8) S22-15734 S22-15532 — 1 — —
High Torque Override (Fig. 8) S22-15532 S22-15534 — — 1 —
Comp. Override (Fig. 10) S22-15530 S22-15530 — — — 1
3 O-Ring, 90 S-1 ARP 906 691-00906 691-00906 2 2 2 2
4 Elbow 492-15017 492-15017 1 1 1 1
5 Elbow 498-00050 498-00050 1 1 1 1
645
0Swivel Nut Ell 492-15190 492-15190 1 1 1 1
7 Tube 032-91887 032-92189 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 032-91881 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
8
7
4
1
3
3 5 6
2
9
2
7
43
8
1
9
356
7
43
2
1
9
3 5 6
9
8NOT SHOWN
356
1
9
7
43
8
2
NOT SHOWN
10 11 12 13 14
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 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 (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 75 lb.•ft., 102 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 75 lb.•ft., 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 5 lb.•ft., 6.78 N•m.
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 for the P16 must be .45 +/- .03 in., 11,4 +/- 0,76 mm, dimension for the P09
must be .655 +/- .03 in., 16,6 +/- 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 1/4, 6,35 mm below sur-
face, 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 20 ft.•lbs., 27 Nm.
14. Install coil on proportional valve. Torque to 20-25 in.•lbs., 2,2-2,8 Nm max.
15. Assemble all other components into body (16) per above drawing. Torque the plug
(12) to 75 lb.•ft., 102 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 75 lb.•ft., 102 Nm.
1. Plumb 1200 PSI , 82,8 bar servo supply to control. Supply 1200 PSI, 82,8 bar to
the electric stroker servo supply port. Note: All pressure references are “above case
pressure” (25 psi, 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 (100-150 mA) to give 50 PSI, 34,5 bar reading on the propor-
tional 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 315 mA for the P09, 335 mA for the P16. 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 225 psi, 16 bar for the P09,
275 psi, 19 bar for the P16.
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 375 mA several times at
approximately 500 PSI, 34,5 bar, 3000 PSI, 207 bar and 6000 PSI, 414 bar system
pressure. Pump stroke should follow amperage smoothly and proportionally. Full to
zero or zero to full stroke should be achieved in .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 5 gpm, 18,9 L/m from each other.
ELECTRIC STROKER
13
FIGURE 5
ELECTRIC STROKER
FIGURE 6
SERVO CAP
TORQUE 75 FT-LB,
102 Nm
PORT
“C2”, SAE-4
ST.THD
TORQUE
11 FT-LB,
15 Nm
DIFFERENTIAL
ADJUSTMENT
ADJUST FOR ZERO FLOW
AT 125 mA ELECTRICAL
COMMAND
PORT “X” SAE-6
STR THD. SERVO INLET
PORT “E” SAE-4 STR THD.
SERVO INLETTO PROP.VALVE
PROPORTIONAL VALVE GAGE
PORT, SAE-4 STR THD.
TORQUE 5 FT-LB,
6,8 Nm
LOCTITE 242
SERVO PRESSURE
TO OPPOSITE SIDE
SAE-6 STR.THD.
TORQUE
75 LB•FT
102 Nm
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ITEM DESCRIPTION PART NO. QTY.
1 Cap (Figure 6) S22-15262 1
2 Orifice 032-92399 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
37 Screw, 1/4-20 x 2-1/4 306-40187 3
38 Plug, aluminum, 7/16-20 449-00013 1
39 O-Ring, 90 S-1 ARP 908 691-00908 1
41 Prop. Pr. Cont.Valve 517-00095 1
42 Coil, 24VDC 517-00096 1
Coil, 12VDC 517-00097
43 Connector 167-01008-8 1
44 O-Ring, 90 S-1 ARP 904 691-00904 1
45 Plug, SAE-4 488-35061 1
46 Screw, SHC 10-32 x 1/4 312-09041 2
ITEM DESCRIPTION PART NO. QTY.
1 Cap/Sleeve S22-15260 1
2 Plug 449-00015 2
3 Plug 032-91861 1
4 Spool 032-59482 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 2
8 Spring 032-91863 1
9 Plug, SAE -10 488-35055 1
10 Plug, SAE -4 488-35061 1
11 O-ring, 90 S-1 ARP 904 691-00904 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
17 Cap 449-00612 1
ELECTRIC STROKER
PARTS LIST FOR FIGURE 5
electric stroker S22-15305
PARTS LIST FOR FIGURE 6
servo cap S22-15262
14
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ELECTRIC STROKER
CONTROL CAP DISASSEMBLY
ASSEMBLY
PARTS LIST FOR FIGURE 7
control cap assembly S22-15256
15
FIGURE 7
CONTROL CAP ASSEMBLY
ITEM DESCRIPTION PART NO. QTY.
1 Control Cap 032-91764 1
2 Plug 449-00015 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 75 lb.•ft., 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 46 lb.•ft., 62
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 75 lb.•ft., 102 Nm. Install plug (21). Torque to 46
lb.•ft., 62 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 75 lb.•ft., 102 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 242 on threads of screw (3), lubricate the shank, thread
through the cap into the control piston, and torque to 5 lb.•ft., 6,78 Nm.
11. Measure height from control cap to top of screw. With control piston at zero stroke,
dimension for the P16 must be .45 +/- .03 in., 11,4 +/- 0,76 mm, dimension for the P09
must be ..655 +/- .03 in., 16,6 +/- 0,76 mm.
12. Press dowel (30) into body (16), through the link assembly (28), to 1/4”, 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 plug (11) to 46 lb.•ft., 62 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 75 lb.•ft., 102 Nm.
TORQUE LIMITER OVERRIDE
TORQUE LIMITER OVERRIDE
DISASSEMBLY
ASSEMBLY
16
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TORQUE LIMITER OVERRIDE
17
FIGURE 8
TORQUE LIMITER OVERRIDE
HIGH FLOW
PRESSURE
ADJUST.
TORQUE
46 LB•FT
62 Nm
HIGH PRESSURE
FLOW
ADJUST.
LOCTITE 242
TORQUE 5 LB.•FT.
6,78 Nm
PARTS LIST FOR FIGURE 8
torque limiter override
P09 code J S22-15734
P09 code K S22-15532
P16 code J S22-15532
P16 code K S22-15534
P09 P16 QTY.
ITEM DESCRIPTION PART NO. PART NO. **J **K
1 Cap (Figure 9) S22-15274 S22-15274 1 1
3 Screw 032-91461 032-91461 1 1
5 Clevis pin 321-40000 321-40000 1 1
6 Spring, Compression 032-92100 032-92100 1 1
7 Plug, Avseal 447-00026 447-00026 1 1
8 Screw 032-91445 032-91445 1 1
9 Nut, Hex Jam 1/4-20 UNC 340-00038 340-00038 1 1
10 Hex Nut, 3/4-16 UNF 032-91449 032-91449 1 1
11 Plug, 8HP N-S 488-35018 488-35018 1 1
14 O-Ring, 90 S-1 ARP 908 691-00908 691-00908 1 1
15 Screw, Primary Adjust 032-91446 032-91446 1 1
16 Body assembly S22-15397 S22-15397 1 1
17 Outer Spring – J Version 032-91440 032-91440 1 —
Outer Spring – K Version 032-91440 032-91448 — 1
18 Inner Spring – J Version 032-92240 032-91441 1 —
Inner Spring – K Version 032-91441 032-91447 — 1
19 Spring Retainer 032-91819 032-91819 1 1
21 Spool 032-91438 032-91438 1 1
23 O-ring, 70 S-1 ARP 118 671-00118 671-00118 2 2
25 Plug, 12 HP5N-S 488-35014 488-35014 1 1
26 O-Ring, 90 S-1 ARP 912 691-00912 691-00912 1 1
27 Sleeve 032-91437 032-91437 1 1
28 Arm assembly S22-15520 S22-15520 1 1
29 O-Ring, 70 S-1 ARP 035 671-00035 671-00035 1 1
30 Dowel Pin, 1/8 Dia. x 1.75 Lg.. 324-20828 324-20828 1 1
33 Screw, SHC 10-32 x 1/4 312-09041 312-09041 2 2
34 Nut 032-91645 032-91645 1 1
35 O-Ring, 70 S-1 ARP 010 671-00010 671-00010 1 1
TORQUE
75 LB•FT
102 Nm
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ITEM DESCRIPTION PART NO. QTY.
1 Cap-Sleeve Assembly S22-15279 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, SAE -10 488-35055 1
13 O-Ring, 90 S-1 ARP 910 691-00910 2
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 Cover 032-91761 1
20 Screw, 1/2-20 x 2-1/2 312-35060 1
21 Plug, SAE -8 488-35018 1
22 O-ring 90 S-1 ARP 908 691-00908 1
23 Soc. Setscrew 5/16-24 x 1-1/4 312-13180 1
24 O-Ring, 90 S-1 ARP 905 671-00905 1
25 Acorn Nut 036-33474 1
26 Plug 449-00015 1
27 Plug, SAE -4 488-35061 1
28 O-ring, 90 S-1 ARP 904 691-00904
29 Plug, SAE -5 488-35020 1
30 O-Ring, 70 S-1 ARP 015 691-00015 1
31 O-Ring, 70 S-1 ARP 008 671-00008 1
32 Orifice 035-40489 1
TORQUE LIMITER OVERRIDE
PARTS LIST FOR FIGURE 9,
torque limiter override cap S22-15274
18
FIGURE 9
TORQUE LIMITER OVERRIDE CAP
SYSTEM PRESS. SAE-10
TORQUE 75 LB-FT, 102 Nm PORT
C1, SAE-4
ST.THD
TORQUE
11 FT-LB,
15 Nm
VENT CONN.“V”
SAE-8 ST.THD.
TORQUE 46 FT-LB,
62 Nm
DIFFERENTIAL
ADJUSTMENT
COMP.
ADJUSTMENT
SERVO PRESSURE
FROM OPPOSITE SIDE
SAE-6 STR.THD.
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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) to remove all load. Turn in outer adjust-
ing screw (8) to go solid. Caution! do not apply over 10 lb.•in., 1,2 Nm torque to avoid
damage to internal parts!
6. Start prime mover with system relief set at 500 PSI., 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 1500 PSI, 103 bar.
9. Adjust compensator differential spool pressure to 200 PSI, 13,8 bar. This is accom-
plished by adjusting the differential screw until the difference in pressure readings
between the system pressure and compensator vent gages installed in the compensator
cap is 200 PSI, 9,3 bar. (It may be necessary to change differential to gain stability. Use
caution when exceeding 250 PSI, 17 bar to avoid spring going solid, preventing compen-
sator action.) When correct, lock in place and install cap on differential adjustment.
10. Set the compensator to 3000 PSI, 207 bar, 6000 PSI, 414 bar, and 7250 PSI, 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 150 PSI, 10,3 bar from the compen-
sator setting. The control should be steady and stable at all conditions.
11. Reduce pressure to 150 PSI, 10,3 bar below the compensator setting. Pump should
return to full stroke. Repeat two or more times. Compensator setting should be repeat-
able.
12. Set compensator adjustment to at least 500 PSI, 34.5 bar above the required setting,
or 7000 PSI, 483 bar.
Set the torque limiter by using the formula:
HP=P•Q / (Eff.•1714)
where P = Pressure in PSI
Q = flow in GPM
Eff. = overall efficiency
or kW = P•Q/(Eff.•600)
where P = pressure in Bar
Q = flow in l/m
Eff. = overall efficiency
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 6000 PSI, 414 Bar if not oth-
erwise 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 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 75 lb.•ft., 102 Nm. Torque plug (21) to
46 lb.•ft., 62 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 75 lb.•ft., 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 500 PSI, 35 bar. Apply a load to
the pump.
5. Set pump control to full displacement. Pump should go to full displacement at 500
PSI, 35 bar.
6. Increase system relief valve until compensator de-strokes pump to zero displace-
ment. Set compensator to 1500 PSI, 103 bar.
7. Adjust compensator differential spool pressure to 200 PSI, 13,8 bar. This is accom-
plished by adjusting the differential screw until the difference in pressure readings
between the system pressure and compensator vent gages installed in the compensator
cap is 200 PSI, 13,8 bar. (It may be necessary to change differential to gain stability. Use
caution when exceeding 250 PSI, 17 bar to avoid spring going solid, preventing compen-
sator action.) When correct, lock in place and install cap on differential adjustment.
8. Set the compensator to 3000 PSI, 207 bar, 6000 PSI, 414 bar, and 7250 PSI, 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 150 PSI, 10,3 bar from the com-
pensator setting. The control should be steady and stable at all conditions.
10. Reduce pressure to 150 PSI, 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 6000 PSI, 414 Bar if not oth-
erwise noted.
COMPENSATOR OVERRIDE
COMPENSATOR OVERRIDE
DISASSEMBLY
ASSEMBLY
TEST AND ADJUSTMENT
20
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