Denison Hydraulics Premier Series Operating and installation instructions

DENISON HYDRAULICS
Premier Series
piston pumps for open circuits
P12 & P200
service information
Publ. LT2-00054-2-A replaces LT2-00054-2 Revised 5/03
Internet http://www.denisonhydraulics.com E-mail: [email protected]
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CONTENTS
2
TITLE PAGE
Rework limits..............................................................................................14
Rear drive adapters....................................................................................15
Conversion..................................................................................................16
Reassembly................................................................................................17
Controls......................................................................................................21
Pressure compensator............................................................................23
Maximum Volume Stop; Handwheel......................................................26
Buck-up cap assembly..........................................................................27
Torque limiter..........................................................................................28
Load sensing control..............................................................................32
Load sensing torque limiter..................................................................35
Rotary servo............................................................................................39
Hydraulic stroker....................................................................................43
Electrohydraulic stroker........................................................................46
PQ control................................................................................................50
Control tubing; Control cap..................................................................54
Compensator override control..............................................................55
Torque limiter override control..............................................................57
Testing........................................................................................................60
Rotary servo test....................................................................................60
Compensator test....................................................................................62
Hydraulic stroker test............................................................................64
Electrohydraulic stroker test..................................................................65
Torque limiter and torque limiter override test....................................66
Load sensing torque limiter test............................................................68
PQ control test........................................................................................70
Final pump test.......................................................................................71
Tools............................................................................................................73
Characteristics............................................................................................75
Ordering code............................................................................................78
Seal kit..................................................................................P12 S22-12830
............................................................................................P200 S22-12831
....................................................................P12 with "X" control S22-16220
..................................................................P200 with "X" control S22-16221
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 resistant 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 publication have been
compiled for the use and convenience of our customers from information furnished by the
manufacturer; and we can not, and do not, accept any responsibility for the accuracy or
correctness of any description, calculation, specification, or information contained herein. No
such description, calculation, specification, 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 on this publication on an “as-is” basis, and disclaim any implied
warranty, including any warranty of merchantability or warranty of fitness for any
particular purpose 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 on this publication. Further, we reserve the right
to revise or otherwise make product improvements at any time without notification.
Port Identification........................................................................................3
Start up Procedure......................................................................................8
Trouble shooting charts..............................................................................9
Exploded view of pump..............................................................................11
Parts list......................................................................................................12
Load sensing test....................................................................................63 3
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IDENTIFICATION OF PORTS AND ADJUSTMENTS
3
....................DESCRIPTION........................................................................................P12 . . . . . . . . . . . . . .P200
PORT A......INLET..........................................................................................3.5" SAE CODE 61.3.5" SAE CODE 61
..........................................................................................................................5/8-11 SCREWS . . . .M16-2 SCREWS
PORT B ......SYSTEM....................................................................................1-1/2 SAE CODE 62 .1-1/2 SAE CODE 62
..........................................................................................................................5/8-11 SCREWS . . . .M16-2 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-24. . . . . . . . . .1-1/2 BSPP
PORT D1....CASE DRAIN......................................................................................SAE-24. . . . . . .. . .1-1/2 BSPP
PORT DG....DRAIN GAGE, AIR BLEED PORT......................................................SAE-4. . . . . . . . . . .1/4BSPP
PORT AG ....INLET GAGE........................................................................................SAE-4 . . . . . . . . . . .1/4 BSPP
PORT BG....SYSTEM GAGE....................................................................................SAE-6. . . . . . . . . . .1/4 BSPP
PORT BG1 ..ALTERNATE SYSTEM GAGE ............................................................SAE-6 . . . . . . . . . . .1/4 BSPP
PORT E ......ELECTROHYDRAULIC STROKER SERVO SUPPLY ........................SAE4 . . . . . . . . . . .1/4 BSPP
PORT H ......HYDRAULIC STROKER SIGNAL ......................................................SAE-4 . . . . . . . . . . .1/4 BSPP
PORT LS ....LOAD SENSING LINE (SEE PAGE 4) ................................................SAE-4 . . . . . . . . . . .1/4 BSPP
PORT V......COMPENSATOR, TORQUE LIMITER, LOAD SENSING VENT........SAE-8. . . . . . . . . . .3/8BSPP
PORT V1 ....SERVO VENT ......................................................................................SAE-4 . . . . . . . . . . .1/4 BSPP
PORT X ......SERVO SUPPLY ..................................................................................SAE-8 . . . . . . . . . . .3/8 BSPP
PORT XG ....SERVO GAGE ....................................................................................SAE-10 . . . . . . . . . .1/2 BSPP
XG
FLUID CONNECTIONS
CCW ROTATION SHOWN
TIGHTENING TORQUE FOR HYDRAULIC PLUGS
PORT SIZE ft-lbs Nm
SAE-4 11 15
SAE-6 18 24
SAE-8 46 62
SAE-10 75 102
SAE-14 130 175
SAE-20 225 305
1/8 BSPP 7 9
1/4 BSPP 18 24
3/8 BSPP 18 24
1/2 BSPP 93 126
1-1/2 BSPP 288 390
SAE-257
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IDENTIFICATION OF PORTS AND ADJUSTMENTS
4
P200
P12
P200
P12
P200
P12
P200
P12
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IDENTIFICATION OF PORTS AND ADJUSTMENTS
5
P12
P200
P12 P200
P200
P12
P12
P200
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6
"X"-PQ CONTROL
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IDENTIFICATION OF PORTS AND ADJUSTMENTS
7
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START UP
8
START UPPROCEDURE 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
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.
DGtill fluid runs clear.
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TROUBLESHOOTING
9
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 deposts.
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
10
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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Figure 1
Exploded view of pump
with
pressure compensator control
Ref. figure 2
Indicator Assembly (52)
S22-15943
item description part no. qty.
1 Pivot nut 032-92491 1
2 Indicator 033-70624 1
3fork032-924901
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
8O-ring, 70 S-1 ARP914671-009141
9 Retaining ring 356-65070 1
PARTS LIST FOR INDICATOR ASSEMBLY
PUMP PARTS LISTS
11
(For PQ Control)
58
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PUMP PARTS LISTS
12
item description part no.
P12-SAE part no. P200-ISO P200-DIN 50mm P200-DIN 60mm qty.
1 shaft assembly 1
keyed, no rear drive S22-16523 S22-16527 S22-16531 S22-16548
a (shaft) 032-92961 032-92962 032-92967 032-92969
b (bearing) 230-82215 230-82215 230-82215230-82217
c (seal) 620-82080 620-82099 620-82099 620-82051
d (key) 033-71514 211-40000 032-92264 032-92246
e (seal retainer) 032-91269 032-91269 032-91269 032-92973
keyed, with rear drive S22-16524 S22-16528 S22-16532 S22-16549
a (shaft) 032-92903 032-92908 032-92968 032-92970
b (bearing) 230-82215 230-82215 230-82215230-82217
c (seal) 620-82080 620-82099 620-82099 620-82051
d (key) 033-71514 211-40000 032-92264 032-92246
e (seal retainer) 032-91269 032-91269 032-91269 032-92973
splined, no rear drive S22-16525 S22-16529 S22-16533 S2216550
a (shaft) 032-92677 032-92974 032-92965 032-92971
b (bearing) 230-82215 230-82215 230-82215230-82217
c (seal) 620-82080 620-82099 620-82099 620-82051
e (seal retainer) 032-91269 032-91269 032-91269 032-92973
splined, with rear drive S22-16526 S22-16530 S22-16534 S22-16551
a (shaft) 032-92890 032-92975 032-92966 032-92972
b (bearing) 230-82215 230-82215 230-82215230-82217
c (seal) 620-82080 620-82099 620-82099 620-82051
e (seal retainer) 032-91269 032-91269 032-91269 032-92973
4 retainer 356-65130 356-65130 1
5Quad Ring 605-00915 605-00915 1
6 cradle 032-92682 032-92907 1
cradle, PQ control 032-93022 032-93023
7 housing, no rear drive 032-92610 032-92905 1
housing, no rear drive, PQ control 032-93024 032-93025
housing, with rear drive 032-92888 032-92906
housing, with rear drive, PQ control 032-93026 032-93027
8O-ring, 70 S-1 ARP 268671-00268 671-00268 1
9 screw, SHC 361-11213 361-11213 12
10 cam assembly S22-16537 S22-16537 1
cam assembly, PQ control S22-16668 S22-16668
11 bearing 032-92679 032-92679 1
12 screw, SHC 361-10234 361-10234 7
14 barrel & port plate assembly CW S22-16223 S22-16223 1
barrel & port plate assembly CCW S22-16535 S22-16535
16 dowel pin 324-21610 324-21610 1
17 piston & shoe assembly S22-16238 S22-16238 1
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PUMP PARTS LISTS
13*see controls section for quantity
item description part no.
P12-SAE part no. P200-ISO/DIN qty.
18 Belleville washer 032-91597 032-91597 3
19 stop 032-92728 032-92728 1
20 retainin
g
rin
g
032-92707 032-92707 1
21 screw, button head (PQ control) 353-25079 353-25079 2
22 wear plate 032-92695 032-92695 1
23 lockwasher 348-10016 348-10016 2
24 bearin
g
032-91602 032-91602 1
25 washer 345-10012 345-10012 2
26 screw, SHC 361-08200 361-08200 4
27 O-rin
g
, 90 S-1 ARP 013 671-00013 671-00013 6
28 cam/bearin
g
retainer 032-92708 032-92708 2
29 bearin
g
, h
y
drostatic cam (PQ control) 032-93028 032-93028
30 O-rin
g
, 70 S-1 ARP 152 671-00152 671-00152 2
31 off stroke control side (see
p
a
g
e 16) 1
buck-up cap (comp, torque limiter, load sensin
g
) S22-15653 S22-15653
electric stroker S22-16001 S22-16002
h
y
draulic stroker S22-16003 S22-16004
rotar
y
servo S22-16005 S22-16006
PQ control S22-15963 S22-15964
32 488-35061 447-01004 2
33 O-rin
g
, 90 S-1 ARP 904 691-00904 691-00904 2
34 screw, SHC 361-08250 361-08250 2
36 O-rin
g
, 70 S-1 ARP 010 (PQ control) 671-00010 671-00010 1
39 rin
g
(qt
y
. 1 for servo, electric & h
y
d. Stroker) 032-92856 032-92856 2
40 O-rin
g
, 90 S-1 ARP 906 691-00906 691-00906 2
41 488-35041 447-01004 2
42 bearin
g
(qt
y
1 for PQ control) 032-92683 032-92683 2
43 slide link 032-92706 032-92706 1
44 control piston (compensator, torque limiter) 032-92710 032-92710 1
control piston (servo, electric & h
y
raulic stroker) S22-17828 S22-17828
control piston (PQ control) 032-93031 032-93031
45 thrust washer 032-91599 032-91599 1
46 retainer, 0.062" / 0.060" thick, blue dot 032-92949 032-92949 1
retainer, 0.060" / 0.058" thick, red dot 032-92948 032-92948
retainer, 0.058" / 0.056" thick,
g
reen dot 032-92947 032-92947
retainer, 0.056" / 0.054" thick,
y
ellow dot 032-92946 032-92946
retainer, 0.054" / 0.052" thick, white dot 032-92945 032-92945
47 screw, FHCHCS (qt
y
1 for PQ control) 316-50000 316-50000 2
48 O-rin
g
, 90 S-1 ARP 920 691-00924 691-00924 1
50 on stroke control side (see
p
a
g
e 16) 1
compensator S22-15311 S22-15312
low torque limiter S22-15732 S22-15733
hi
g
h torque limiter S22-15315 S22-15316
load sensin
g
S22-15536 S22-15537
low torque limiter with load sensin
g
S22-16193 S22-16194
hi
g
h torque limiter with load sensin
g
S22-16191 S22-16192
compensator override S22-16007 S22-16008
low torque limiter override S22-16183S22-16184
hi
g
h torque limiter override S22-16009 S22-16010
control cap, servo S22-15256 S22-15272
maximum volume stop, PQ control S22-16126 S22-16126
51 shippin
g
plu
g
449-00021 449-00611 1
52 plu
g
, SAE-14 488-35030 488-35030 1
indicator assembl
y
(see fi
g
ure 2) S22-15943 S22-15943
53 O-rin
g
, 90 S-1 ARP 914 691-00914 691-00914 1
54 plu
g
, 1/4 pipe (PQ control) 431-90404 431-90404 2
55 plu
g
, 1/16 pipe (PQ control) 431-90104 431-90104 1
56 fittin
g
, pass throu
g
h (PQ control) S22-16161 S22-16161 1
57 488-35061 447-01004 1
58 Shoe Retainer 032-92680 032-92680 1
Seal Kit S22-12830 S22-12831
Seal Kit, with PQ control S22-16220 S22-16221
plug, SAE-4, (1/4 BSPP)
35 Screw, HHC, M12 x 1.75 x 60 mm lg. 363-12210 363-12210 *
Screw, HHC, M12 x 1.75 x 90 mm lg. (L) 363-12240 363-12240 *
Screw, HHC, M12 x 1.75 x 80 mm lg. (E,H,R,J,K) 363-12225 363-12225 *
plug, SAE-6, (1/4 BSPP)
49 plug, SAE-24, (1-1/2 BSPP) 488-35062 447-00034 1
plug, SAE-4 (1/4 BSPP)
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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" (4,674mm)
piston shoe face(pocket)*
*shoe face pocket depth must be . 004 (0,10 mm)minimum
WEAR PLATE
The wear plate finish must be 10 µin. (0,25 µm)min., 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 15.
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.
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 ref. see item (50), CW so that piston (44) bottoms out. This positions the cam at
approximately zero stroke allowing removal of the drive shaft. Reference item 1 page 23.
3. Remove socket head cap screws (9). If disassembling PQ Control version, remove tubing and pass thru fitting (56).
3. Remove cradle assembly (6) from the housing. The 3/8-16 threaded hole in end of the shaft is provided for lifting
this assembly.
5. Remove snap ring (4).
6. Remove screws (47) to remove cam bearings (42).
7. Remove shaft, bearing, and seal retainer assembly (1). 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.
12.Remove two screws (34), two washers (25), clearance bearing (24), and two washers (23) from retainer (28).
13.For compensator, torque limiter or load sensing control pumps, wind maximum volume screw CCW until piston (44)
bottoms out.
14.Remove control cap (50) and control cap (31). (Refer to controls section for control disassembly).
15.Insert two tools (T-2) (see page 73) into housing supporting each end of the control piston. The piston must be
moved outward (away from pump center) to remove cam assembly.
16.Lift cam assembly (10) from pump. (Link (43), pistons and shoes and retainer plate(17) (58), wear plate (22), and hold-
down (45 and 46) are part of the cam assembly.)
17.Remove slide link (43), retaining ring (46), thrust washer (45), pistons, shoes & retainer assembly (58) 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.
18.Remove two screws (34), two screws (26), and two retainers (28).
19.Remove Belleville washers (18) and barrel stop (19).
20.Attach tool (T-1) (pg. 73) to barrel assembly (14). (Two M6 screws are required.) Lift barrel from port plate and
housing.
21.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
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.
22.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
14
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SAE REAR DRIVES
code A G B Q C N D E
flange SAE 82-2 SAE 82-2 SAE101-2/4 SAE101-2/4 SAE127-2/4 SAE127-2/4 SAE152-4 SAE165-2/4
coupling 16-4 22-4 22-4 25-4 32-4 38-4 44-4 44-4
item part qty (“A”) (modified “A”) (“B”) (“B-B”) (“C”) (“C-C”) (“D”) (“E”)
1 adapter 1 032-91900 032-91900 032-91309 032-91309 032-91308 032-91649 032-91282 032-91283
2 coupling 1 032-91901 032-92377 032-91361 032-91362 032-91363 032-91648 032-91364 032-91364
3 screw 4 361-16304--8 361-16304-8 361-16304-8 361-16304-8 361-16304-8 361-16304--8 363-16250 363-16250
4O-ring1671-00152671-00152671-00155671-00155671-00159671-00159671-00163671-00165
5 O-ring 1 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159
6washer4350-10109350-10109
assembly S22-15372 S22-15809 S22-12867 S22-12868 S22-12869 S22-12920 S22-12870 S22-12871
REAR DRIVE PARTS LISTS
15
note: 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 S W V
flange ISO 100ISO 125ISO 160ISO 180ISO 180ISO 180ISO 180IS0 200ISO 224
coupling ISO K25N ISO K32N ISO K40N ISO K40N ISO K50N DIN 40-18 DIN 50-24 ISO K50N ISO K50N
item part qty
1adapter1032-91383032-91384032-91385032-92162032-92162032-92162032-92162032-91386032-92963
2 coupling 1 032-91391 032-91390 032-91389 032-91389 032-91388 032-92345 032-92346 032-91388 032-91388
3screw4361-16304-8361-16304-8363-16250 363-16250 363-16250 363-16250 363-16250363-16250 363-16250
4O-ring1671-00155671-00159671-00164671-00167671-00167671-00167671-00167671-00170671-00173
5 O-ring 1 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159 671-00159
6washer4350-10109350-10109350-10109350-10109350-10109350-10109350-10109
assemblyS22-12872S22-12873S22-12874S22-15740S22-15570S22-15933S22-15934S22-12875S22-16543
Figure 3
Rear drive options
ISO 224
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CONVERSION
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 AssemblyS22-16223
CCW - Barrel and Port Plate AssemblyS22-16535
The control piston must be reversed to position it correctly to the control caps. (See step 9 pg. 18)
The control location is reversed. see illustration below.
E, H, R, X CONTROLS
LOCATION (item 31 Fig. 1)
E, H, R, X CONTROLS
LOCATION (item 31 Fig. 1)
Figure 5
CONTROL ORIENTATION VERSUS PUMP ROTATION
16
M, C, J, K, L, V,W CONTROLS
LOCATION (item 50 Fig. 1)
M, C, J, K, L, V,W CONTROLS
LOCATION (item 50 Fig. 1)
Figure 4
CAM BEARINGS/CRADLE ORIENTATION TO HOUSING
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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.
SEALKITS....................................P12S22-12830
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P200S22-12831
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P200S22-16221
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
The following assemblies include shaft, key when applicable, bearing and
seal:
P12-SAE #P200-ISO #
Keyed, no rear drive assemblyS22-16523 S22-16527
Keyed, with rear drive assemblyS22-16524S22-16528
Splined, no rear drive assemblyS22-16525S22-16529
Splined, with rear drive assemblyS22-16526S22-16530
P200-DIN 60mm
Keyed, no rear drive assembly S22-16531
Splined, no rear drive assembly S22-16533
Splined, with rear drive assembly S22-16534
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.
Several screws require a thread lock compound for locking in position. When required use Loctite#242 unless otherwise
specified.
PUMP REASSEMBLY INSTRUCTIONS
ASSEMBLY
Refer to illustration, see figure 1
See page 22 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.
2. Install plugs (32), (41) and (54) 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 Port Plate for CCW Shaft Rotation
SLOT FOR PORT
BLOCK LOCATING PIN
(Ref. Barrel and Port Plate Assembly S22-16223) (Ref. Barrel and Port Plate Assembly S22-16535)
17
SEALKITS (WITH X CONTROL). ..................P12S22-16220
P200-DIN 50mm S22-16548
S22-16550
Keyed, with rear drive assembly S22-16532 S22-16549
S22-16551
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PUMP REASSEMBLY INSTRUCTIONS
18
4. Press bearing outer race (11) into housing (7).
BARREL AND INNER RACEASSEMBLY
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. Five different retainers (46) are available for setting the shoe holddown. Each retainer is
marked: white dot.053" (1,35 mm)thick, yellow dot.055" (1,40 mm)thick, green dot.057"
with the dot side up,that will fit in the groove on the center post and allow a clearance of .003"-.005"
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 retainers
(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 clearancebetween 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
any shoe, and a.005 (0,127 mm)feeler gage must not gounder any
(1,45 mm)thick, red dot.059" (1,50 mm)thick, and blue dot.061" (1,55 mm)thick. Install the thickest retainer
(0,076-0,127 mm)between the shoe and wear plate. A.003" (0,076 mm)feeler gage must gocompletely under
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- Continued -
Rocker cradle assembly
20.Apply threadlocking compound to two screws (47) and assemble two cam bearings (42) to cradle (6). Torque to 33
lbs-in., (3.8 Nm).
21. Press bearing (1b) on shaft (1a). Press on inner race only.
22. Apply over 360o bead of gasket sealant to seal retainer (1e) per following sketch. Press shaft seal
(1c) into seal retainer (1e).
23. Install shaft seal and retainer on shaft using Tool T-4 (page 74) to protect seal.
24. Install "O" ring (5) in cradle (6).
25. Press seal retainer and bearing and shaft assembly into bore of cradle (6)
using Tool T-3 (page 74).
26. Install snap ring (4) to cradle.
27. Install "O" ring (8) to rocker cradle. 28. Install retaining ring (20) on shaft.
29. Center Belleville washers and barrel stop. Lower rocker cradle assembly
into pump housing with the step in the rocker cradle correctly positioned
so that clearance is provided for slide link (43). The 3/8-16 threaded
hole in the end of shaft should be used to support the assembly. The
shaft spline must first engage the splined barrel stop (19), thru the
Belleville washers (18) and engage the barrel spline.The assembly will
then rest on the cam.
30. Install socket head cap screws (9) as shown. Torque evenly to 57 ft-lb
(77 Nm). Install case drain plug (49) and shipping plug (51). If pump
indicator hole.
pass thru fitting (56) into housing, being
careful that O-ring enters hole in cradle
without damage.
INDICATOR ASSEMBLY OPTION
See figure 2.Toinstall indicator assembly, loosen setscrew (6), remove indicator
(2) and slide shaft out of nut (1). Guide fork into indicator hole in housing to engage
the pin on the hanger. A1/4-20 SHCS or threaded rod may be used to hold the
shaft. Slide nut (1) over shaft and tighten nut in threaded hole. Pull shaft out to slip
retaining ring (9) into groove in shaft. Use maximum volume stop to set pump on
tion.
PUMP REASSEMBLY INSTRUCTIONS
19
ref. Figure 2
Indicator assembly
THREAD LOCK-
ING COMPOUND
33 IN-LB, 3,8 Nm
6
42
47 29
36
21
does not contain stroke indicator, install plug (52) and O ring (53) in
31. If installing X model pump, install
zero stroke (9.5turns from full). Install indicator, set pointer on0and lock in posi-
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CONTROLS ASSEMBLY
Remove cap tools T-2 from housing and replace with control cap assemblies (50) and (31). The control caps must be
positioned on the housing for either CW or CCW pump rotation. See figure 5 for correct orientation. The control piston
(44) was assembled previously for the correct pump rotation. Install eight hex head cap screws (35) into caps and
torque to housing with 75 lbs-ft. (102 Nm).
20
M, C, J, K, L, V,W
CONTROLS LOCATION
E, H, R, X
CONTROLS LOCATION M, C, J, K, L, V,W
CONTROLS LOCATION
E, H, R, X
CONTROLS LOCATION
If the pump has a rear drive feature, assemble coupling and adapter.See illustration, figure 3 (page 15).
ref. Figure 5
PUMP REASSEMBLY INSTRUCTIONS
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