DENISON HYDRAULICS Premier series open circuit pumps P16 & 260 C-mod. service information

Transcription

1 DENISON HYDRAULICS Premier series open circuit pumps P6 & 60 C-mod. service information Publ. S-AM0-B replaces S-AM0-A, S-AM0-A, S-AM0-A, S-AM06-A Revised /0 Internet:

2 CONTENTS TITLE PAGE Port Identification... Start up Procedure...7 Trouble shooting charts...8 Disassembly...0 Rework limits... Parts list... Rear drive adaptors...6 Conversion...7 Reassembly...8 Controls... Testing...6 Tools...77 Characteristics...79 Ordering code...8 Seal kit...p6 S P6 with X CONTROL S-60...P60 ISO S P60 DIN S P60 with X CONTROL S-6 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.

3 IDENTIFICATION OF PORTS AND ADJUSTMENTS XG CCW ROTATION SHOWN H FLUID CONNECTIONS...DESCRIPTION...P6 C MOD P60 C MOD PORT A...INLET...-/ SAE CODE 6.-/ SAE CODE 6 /8- SCREWS M6- SCREWS PORT B...SYSTEM...-/ SAE CODE 6 -/ SAE CODE 6 /8- SCREWS M6- SCREWS PORT C...OFF-STROKE CYL. GAGE...SAE / BSPP PORT C...ON-STROKE CYL. GAGE...SAE / BSPP PORT D...CASE DRAIN...SAE / BSPP PORT D...CASE DRAIN...SAE / BSPP PORT DG...DRAIN GAGE, AIR BLEED PORT...SAE / BSPP PORT AG...INLET GAGE...SAE / BSPP PORT BG...SYSTEM GAGE...SAE / BSPP PORT BG...ALT. SYS. GAGE...SAE / BSPP PORT E...ELECTROHYDRAULIC STROKER SERVO SUPPLY...SAE / BSPP PORT H...HYDRAULIC STROKER SIGNAL...SAE / BSPP PORT LS...LOAD SENSING LINE...SAE / BSPP PORT V...COMPENSATOR, TORQUE LIMITER, LOAD SENSING VENT...SAE /8 BSPP PORT V...OVERRIDE COMP, OVERRIDE TORQUE LIMITER VENT...SAE / BSPP PORT V...SERVO VENT...SAE / BSPP PORT X...SERVO SUPPLY...SAE /8 BSPP PORT XG...SERVO GAGE...SAE / BSPP

4 IDENTIFICATION OF PORTS AND ADJUSTMENTS CW ROTATION J0, J0, K0, K0, L0, L0 Shown TORQUE LIMITER WITH ADJ. MAX. VOL. STOP, CCW and TORQUE LIMITER WITH HANDWHEEL ADJ. MAX. VOL. STOP, CCW V LOAD SENSING WITH ADJ. MAX. VOL. SCREW STOP, CCW UNIT PRESSURE RATING 000 PSI MAXIMUM WITH THIS CONTROL C C Torque Limiter Adjustment Differential Adjustment Compensator Adjustment B Differential Adjustment LS Compensator Adjustment B V Compensator Adjustment V

5 Zero Volume Stop XG C X Zero Volume Stop Servo Pressure Inlet X XG C XG C X V V Zero Volume Stop V Rotary Input Shaft Maximum Stroke Adjustment Zero flow Adjustment E Zero flow Adjustment H Differential Adjustment E (P60) B Differential Adjustment B Differential Adjustment X X H (P6) H (P 60) R ROTARY SERVO E ELECTRO-HYDRAULIC STROKER H HYDRAULIC STROKER CW ROTATION IDENTIFICATION OF PORTS AND ADJUSTMENTS B

6 IDENTIFICATION OF PORTS AND ADJUSTMENTS *0 CONTROL CAP WITH MAX. VOLUME STOP *J TORQUE LIMITER OVERRIDE W/MAX. VOLUME STOP or *K TORQUE LIMITER OVERRIDE W/MAX. VOLUME STOP CW ROTATION *P COMPENSATOR OVERRIDE W/MAX. VOLUME STOP Differential Adjustment C V Maxium Volume Adjustment C V Differential Adjustment B B B V Maxium Volume Adjustment V Compensator Adjustment Torque Limiter Adjustment V Compensator Adjustment Maxium Volume Adjustment 6

7 START UP 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 and motor 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. 7

8 TROUBLESHOOTING 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.. 8

9 TROUBLESHOOTING 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 9

10 DISASSEMBLY INSTRUCTIONS Figure Volume indicator assembly item (For PQ Control) Figure Exploded view of pump with pressure compensator control 0

11 DISASSEMBLY INSTRUCTIONS 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 page 6. 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 lbs., 7. Kg. Refer to illustration, see figure and. Remove plug (9) and drain oil from pump. Position pump with shaft up.. Wind maximum volume screw ref. see item (0), CW so that piston () bottoms out. This positions the cam at approximately zero stroke allowing removal of the drive shaft. Reference item page 7.. Remove socket head cap screws (9). If disassembling PQ Control version, remove tubing and pass thru fitting (6).. Remove cradle assembly (6) from the housing. The M-0 threaded hole in end of the shaft is provided for lifting this assembly.. Remove snap ring (). 6. Remove screws () and (7) to remove cam bearings (9) and () as applicable. 7. Remove shaft (), 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 (c) from the retainer (e) if necessary. 9. Remove retaining ring (0). 0.Press bearing off shaft if necessary. Press against bearing inner race..if pump contains a volume indicator assembly (): Refer to. Figure : Remove indicator pointer (), retaining ring (9) and pivot nut () from pump housing. Remove pivot shaft and fork assembly () and () through the hole..remove two screws (), two washers (), clearance bearing (), and two washers () from retainer (8)..Wind maximum volume screw CCW until piston () bottoms out..remove control cap (0) and control cap (). (Refer to controls section for control disassembly).. Insert two tools (T-) (see page 77) into housing supporting each end of the control piston. The piston must be moved outward (away from pump center) to remove cam assembly..lift cam assembly (0) from pump. (Link (), pistons and shoes and retainer plate(7), wear plate (), and holddown ( and 6) are part of the cam assembly.) 6.Remove slide link (), retaining ring (), thrust washer (6), pistons, shoes & retainer assembly (7) and wear plate (). The pins for the slide link and for the indicator have been pressed into the rocker cam and should not be removed. 7.Remove two screws (), two screws (6), and two retainers (8). 8.Remove Belleville washers (8) and barrel stop (9). 9.Attach tool (T-) (pg. 6) to barrel assembly (-). (Two M6 screws are required.) Lift barrel from port plate and housing. 0.The inner race of bearing () 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 (). Replace with /6-8 UNC x 6 / 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..remove port plate ref. see item (), and alignment pin (6), from port block. The barrel bearing outer race () should only be removed from housing if worn, damaged or closer inspection is needed. A bearing puller should be used for removal. REWORK LIMITS OF WEAR PARTS item maximum rework from original dimension minimum dimension after rework wear plate.00", 0, mm.0", 6,096 mm piston shoe face(pocket) *.7", 0,60 mm *shoe face pocket depth must be.00, 0,00 mm minimum WEAR PLATE The wear plate finish must be 0 µin., 0, µm min., flat within.000", 0,07 mm and parallel to the backside within.00", 0,0 mm total indicator reading. PISTON SHOE The piston shoe wear face finish must be µin.,, µm min, and must be lapped in a set with the retainer plate. All shoe sole thicknesses to be within.00", 0,0 mm after lapping. The maximum permissible shoe and piston axial looseness is.00", 0, mm.

12 PUMP PARTS LISTS (For PQ Control) Ref. Figure Exploded view of pump with pressure compensator control

13 PUMP PARTS LISTS item description part no. part no. qty. P6-SAE P60-ISO shaft assembly keyed, no rear drive S-76 S-8 a (shaft) b (bearing) c (seal) d (key) e (seal retainer) keyed, with rear drive S-89 S-86 a (shaft) b (bearing) c (seal) d (key) e (seal retainer) splined, no rear drive S-77 S-8 a (shaft) b (bearing) c (seal) e (seal retainer) splined, with rear drive (standard) S-86 S-866 a (shaft) b (bearing) c (seal) e (seal retainer) splined, with rear drive (hi-torque, SAE-F) S-86 a (shaft) 0-96 b (bearing) 0-8 c (seal) e (seal retainer) P60-DIN keyed, no rear drive S-680 a (shaft) 0-9 b (bearing) 0-87 c (seal) d (key) 0-96 e (seal retainer) 0-9 keyed, with rear drive S-68 a (shaft) 0-9 b (bearing) 0-87 c (seal) d (key) 0-96 e (seal retainer) 0-9 splined, no rear drive S-68 a (shaft) 0-9 b (bearing) 0-87 c (seal) e (seal retainer) 0-9 splined, with rear drive S-68 a (shaft) 0-9 b (bearing) 0-87 c (seal) e (seal retainer) 0-9 retainer O-ring, 70 S- ARP cradle cradle, PQ control housing, no rear drive housing, no rear drive, PQ control housing, with rear drive housing, with rear drive, PQ control O-ring, 70 S- ARP screw, SHC (6 required in P60) /6 0 cam assembly S-66 S-66 0 cam assembly, PQ control S-960 S-960 bearing screw, SHC barrel & port plate assembly CW, H* S-600 S-600 barrel & port plate assembly CCW, H* S-67 S-67

14 PUMP PARTS LISTS Ref. Figure Exploded view of pump with pressure compensator control (For PQ Control) Ref. figure Indicator Assembly () S-9 PARTS LIST FOR INDICATOR ASSEMBLY item description part no. qty. Pivot nut 0-99 Indicator fork pivot shaft 0-99 glyd ring Soc. setscrew, 0- x / O-ring, 70 S- ARP O-ring, 90 S- ARP Retaining ring

15 PUMP PARTS LISTS item description part no. part no. qty. P6-SAE P60-ISO barrel & port plate assembly CW, Q* S-6 S-6 barrel & port plate assembly CCW, Q* S-6 S-6 barrel & port plate assembly CW, PQ control S-96 S-96 barrel & port plate assembly CCW, PQ control S-96 S-96 6 dowel pin heavy pistons, shoes,retainer assembly (Q, PQ control)* S-89 S-89 (7-) retainer plate ( req d) (7-) heavy pistons and shoes (7 req d) S-89 S-89 lightweight pistons, shoes,retainer assembly (H)* S-7 S-7 (7-) retainer plate ( req d) (7-) lightweight pistons and shoes (7 req d) S-78 S-78 8 Belleville washer stop retaining ring screw, button head (PQ control) wear plate lockwasher bearing washer screw, SHC O-ring, 90 S- ARP cam/bearing retainer bearing, hydrostatic cam (PQ control) O-ring, 70 S- ARP off stroke control side (see page 7) buck-up cap (comp, torque limiter, load sensing) S-6 S-6 electric stroker S-600 S-600 hydraulic stroker S-600 S-600 rotary servo S-600 S-6006 PQ control S-96 S-96 plug, SAE-, / BSPP O-ring, 90 S- ARP none screw, SHC Screw, HHC, M x,7 x 60 mm lg * Screw, HHC, M x,7 x 80 mm lg.(e,h,r,j,k) 6-6- * Screw, HHC, M x,7 x 90 mm lg. (L) * 6 O-ring, 70 S- ARP 00 (PQ control)) ring (qty. for servo, electric & hyd. stroker) ring (servo, electric & hydraulic stroker) O-ring, 90 S- ARP none plug, SAE-6, / BSPP bearing ( for PQ control) slide link control piston (compensator, torque limiter) control piston (servo, electric & hydraulic stroker) control piston (PQ control) bearing retainer, orange,.06",,60 mm thk retainer, blue,.06",,6 mm thk retainer, red,.067",,70 mm thk retainer, green,.069",7 mm thk retainer, yellow,.07",80 mm thk retainer, white,.07",8 mm thk screw, FHSHCS (qty. for PQ control) O-ring, 90 S- ARP none 9 plug, SAE-, -/ BSPP on stroke control side (see page 7) compensator S- S- low torque limiter S- S- high torque limiter S- S-6 load sensing S-6 S-7 compensator override S-6007 S-6008 low torque limiter override S S-600 high torque limiter override S-60 S-60 control cap, servo S-6 S-7 max. volume stop, PQ control S-66 S-66 shipping plug plug, SAE indicator assembly (see figure ) S-9 S-9 O-ring, 90 S- ARP plug, / pipe (PQ Control) plug, /6 pipe (PQ Control) fitting, pass through (PQ Control) S-66 S-66 *Q means solid piston, H means lightweignt piston

16 REAR DRIVE PARTS LISTS Figure Rear drive options SAE REAR DRIVES code A G B Q C N D E flange SAE 8- SAE 8- SAE0-/ SAE0-/ SAE7-/ SAE7-/ SAE- SAE6-/ coupling item part qty ( A ) (modified A ) ( B ) ( B-B ) ( C ) ( C-C ) ( D ) ( E ) adapter coupling screw O-ring O-ring washer assembly S-7 S-809 S-867 S-868 S-869 S-90 S-870 S-87 ISO REAR DRIVES code Z Y X T U L S W V flange ISO 00 ISO ISO 60 ISO 80 ISO 80 ISO 80 ISO 80 IS0 00 ISO 0 coupling ISO KN ISO KN ISO K0N ISO K0N ISO K0N DIN 0-8 DIN 0- ISO K0N ISO K0N item part qty adapter coupling screw O-ring O-ring washer assembly S-87 S-87 S-87 S-70 S-70 S-9 S-9 S-87 S-876 note: item () blanking plate part no item () blanking plate screws

17 CONVERSION Figure CAM BEARINGS/CRADLE ORIENTATION TO HOUSING 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 Assembly S- 600 (H) S-6 (Q) S-96 (PQ control) CCW - Barrel and Port Plate Assembly S- 67 (H) S-6 (Q) S-96 (PQ control) The control piston must be reversed to position it correctly to the control caps. See step 9 pg. 0) The control caps location are reversed. see illustration below. E, H, R, X CONTROLS LOCATION (item Fig. ) C, J, K, L, V, W CONTROLS LOCATION (item 0 Fig. ) C, J, K, L, V, W CONTROLS LOCATION (item 0 Fig. ) Figure CONTROL ORIENTATION VERSUS PUMP ROTATION E, H, R, X CONTROLS LOCATION (item Fig. ) 7

18 PUMP REASSEMBLY INSTRUCTIONS SHAFT SEAL REPLACEMENT See illustration. Remove worn or damaged seal from retainer. Clean Loctite "Master Gasket" from retainer. Install new seal by applying "Master Gasket" to retainer and pressing seal in retainer. SEAL KITS P6 S P60 ISO S P60 DIN S 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: P6-SAE P6-SAE # P60-ISO # P60-ISO # # Keyed, no rear drive assembly S-76 S-8 Keyed, with rear drive assembly S-89 S-86 Splined, no rear drive assembly S-77 S-8 Splined, with rear drive assembly S-86 S-866 Splined, with rear drive (hi-torque) assembly S-86 P60-DIN # Keyed, no rear drive assembly S-680 Keyed, with rear drive assembly S-68 Splined, no rear drive assembly S-68 Splined, with rear drive assembly S-68 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 liquid for locking in position. When required use Loctite # unless otherwise specified. ASSEMBLY Refer to illustration, see figure See page 6 for tightening torque on plugs. Place the port block end of the housing (7) on a suitable surface capable of supporting the pump weight of lbs, 7. Kgs.. Install plugs () with "O" rings into port block. Install plugs () with "O" rings into port block.. Install pin (6) in port block. Position port plate () 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 8

19 PUMP REASSEMBLY INSTRUCTIONS X Model (For PQ Control) Ref. Figure Exploded view of pump with pressure compensator control 9

20 PUMP REASSEMBLY INSTRUCTIONS. Press bearing outer race () into housing (7). BARREL AND INNER RACE ASSEMBLY. Thread seven /6-8 studs into bearing inner race. Lower barrel () over studs and seat. If the inner race is heated to 0 0 F, 6 0 C, barrel will slide into position without force. If race is not heated, longer screws () can be used to draw the race and barrel together. Insert screws () and torque to 0 lbs ft., 0 Nm. See illustration 6. Apply oil to face of port plate and inner bearing race. Attach tool T- 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 (7) into each retainer (8). Apply Loctite #7 to two screws (6) and secure retainer to housing. Torque to 8 lbs-in., 9, Nm. 8. Apply Loctite #7 to two screws () and assemble the other retainer on opposite side of housing. Torque to 8 lbs-in., 9, Nm. 9. Assemble the two piston rings (9) on control piston (). Insert control piston () 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.) For CCW rotation, the long end of the piston is to the left. Insert tools T- (page 77, two required) into housing bores, support each end of the control piston. The piston must be moved outward (away from pump center) so that clearance is provided for installing the rocker cam assembly. 0. Position Belleville washers (8) on barrel, See illustration. To insure proper pump operation and correct barrel holddown force they must be assembled exactly as shown. Place barrel stop (9) on Belleville washers and center the washers and stop on barrel. CAM ASSEMBLY. Set cam assembly (0) on suitable surface protecting cam surfaces from damage during assembly. See illustration. Place wear plate () on cam.. Position pistons-shoes-retainer assembly (7) over center post and against wear plate.. Install thrust washer () over center post.. Six different retainers (6) are available for setting the shoe holddown. Each retainer is marked: white dot.07",,8 mm thick, yellow dot.07",,80 mm thick, green dot.069",,7 mm thick, red dot.067",,70 mm thick, blue dot.06",,6 mm thick and orange dot.06,,60 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.00"-.00", 0,076-0,7 mm between the shoe and wear plate. A.00", 0,076 mm feeler gage must go com pletely under any shoe, and a.00, 0,7 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.00/.00 (,7/,076 mm) SHOE CLEARANCE hand. Rotate 60 o to confirm there is no binding and that each shoe is free in the retainer plate. Oil the assembly thoroughly. 6. Install slide link () on rocker cam pin as shown. 7. Oil barrel bores before installing cam assembly. Lower cam assembly into the housing with the slide link positioned so it will engage into the control piston (). The seven pistons (7) must first be engaged into the barrel bores. Next the slide link () must engage into the control piston (). Continue lowering rocker cam assembly until it is seated on cam/bearing retainers(8). 8. Apply Loctite to two screws () and assemble clearance-bearing () to cam-bearing retainer (8) using the screws (), two washers () and two washers (). Move rocker cam to the right until it is against stop. Set clearance between clearance bearing () and cam at.006", 0, mm. Torque screws to 6 lbs-ft., 8, Nm maintaining the.006", 0, mm clearance. 9.Adjust piston () toward the off stroke control side (). This will place the cam at approximately zero stroke and provide clearance for the shaft installation. 0

21 PUMP REASSEMBLY INSTRUCTIONS (For PQ Control) Ref. Figure Exploded view of pump with pressure compensator control

22 PUMP REASSEMBLY INSTRUCTIONS - Continued - Rocker cradle assembly 0.Apply Loctite to two screws (7) and assemble two cam bearings () to cradle (6). Torque to lbs-in.,,8 Nm. Note: Pumps with PQ control: A special cam, cradle and cam bearing provides a pressure balance to the bearing interface on the control side of the cam. Install plugs () and () to cradle as shown. Install O-ring (6) in cradle. Apply Loctite to two screws () and attach cam bearing (9). Torque to in-lbs,,8 Nm. 6 7 LOCTITE IN-LB,,8 Nm 9 LOCTITE IN-LB,,8 Nm 6. Press bearing (b) on shaft (a). Press on inner race only.. Apply over 60 o bead of Loctite Master Gasket to seal retainer (e) per following sketch. Press shaft seal (c) into seal retainer (e).. Install shaft seal and retainer on shaft using Tool T- to protect seal.. Install "O" ring () in cradle (6).. Press seal retainer and bearing and shaft assembly into bore of cradle (6) using Tool T-. 6. Install snap ring () to cradle. 7. Install "O" ring (8) to rocker cradle. 8. Install retaining ring (0) on shaft. 9. 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 (). The M-0 threaded hole in the end of shaft should be used to support the assembly. The shaft spline must first engage the splined barrel stop (9), thru the Belleville washers (8) and engage the barrel spline. The assembly will then rest on the cam. 0. Install socket head cap screws (9) as shown. Torque evenly to - ft-lbs (6-7 Nm). Install case drain plug (9) and shipping plug (). If pump does not contain stroke indicator, install plug () and O ring () in indicator hole.. If assembling X Model pump, install pass thru fitting (6) into housing, being careful that O-ring enters hole in cradle without damage. INDICATOR ASSEMBLY OPTION See figure. To install indicator assembly, loosen setscrew (6), remove indicator () and slide shaft out of nut (). Guide fork into indicator hole in housing to engage the pin on the hanger. a /-0 SHCS or threaded rod may be used to hold the shaft. Slide nut () 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 zero stroke (0. turns from full). Install indicator, set pointer on 0 and lock in position. ref. Figure Indicator assembly

23 PUMP REASSEMBLY INSTRUCTIONS (For PQ Control) Ref. Figure Exploded view of pump with pressure compensator control

24 PUMP REASSEMBLY INSTRUCTIONS CONTROLS ASSEMBLY Remove cap tools T- from housing and replace with control cap assemblies (0) and (). The control caps must be positioned on the housing for either CW or CCW pump rotation. See figure for correct orientation. The control piston () was assembled previously for the correct pump rotation. Install eight hex head cap screws () into caps and torque to housing with 7 lbs-ft., 0 Nm. E, H, R, X CONTROLS LOCATION C, J, K, L, V, W CONTROLS LOCATION C, J, K, L, V, W CONTROLS LOCATION ref. Figure If the pump has a rear drive feature, assemble coupling and adapter. See illustration, figure. E, H, R, X CONTROLS LOCATION Ref. Figure

25 CONTROLS GENERAL 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 DESCRIPTION OF OPERATION A pilot operated valve spool and sleeve combination is the core of the control function. For the compensator, torque limiter and load sensing controls, system pressure is applied to the input port of a three-way valve, and to one end of the valve spool. A small orifice feeds this pressure to the other end of the spool, and limits pilot flow to approximately in /min.,,9 lpm. 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 end of the control piston a small buck-up piston connects to system pressure. This force, pump timing forces, and a spring combine to put the pump on stroke. PRESSURE COMPENSATOR A spring-loaded cone and seat connected to the spring end of the three-way spool establishes an adjustable pressure limit on this end of the spool. When system pressure reaches this value, flow through the spool creates a pressure difference across the spool. At approximately 0 psi, 7, bar difference, the spool shifts toward the spring, re-directing the control piston port to system 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 meters to maintain the pump pressure at approximately 0 psi, 7, bar above the controlled pressure on the spring side. The spring end of this three-way spool may also be connected to a remote pressure control, through the vent port, V. COMPENSATOR WITH LOAD SENSING CONFIGURATION To use the compensator for load sensing, the V port is connected to the load downstream of a metering valve. The pump will supply approximately 0 psi, 7, bar difference in pressure across the metering valve, and thus controls flow independent of operating pressure. Adjustment of spring load on the three-way spool allows precise control of the differential pressure. LOAD SENSING CONTROL To eliminate thepilot flow, and to control multiple loads, a control designed for load sensing 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 approximately 0 psi to psi,, to 0 bar above load pressure. There is essentially no flow in the sensing line, and the pump supplies the flow required to develop 0 psi to psi,, to 0 bar across the.metering valve to the load. TORQUE LIMITER The product of system pressure and pump displacement must be kept constant for torque limiting. As pressure increases, displacement must reduce, and vice versa. A linkage to the pump control piston slides a sleeve over a pin. The sleeve and pin act as a metering valve. The pin contains a cross drilled hole, and a connecting drilling to one end 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 sleeve to move in the direction to close the cross-drilled hole. Thus, for every position of the pin, there is a corresponding position for the control piston where balance is achieved. At low pressure, high flow, only the outer spring contacts the pin. 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 a constant product of pressure times displacement. The normal compensator function is retained to provide a maximum pressure limit. TORQUE LIMITER WITH LOAD SENSING A modulating valve is mounted to a torque limiter body to provide a load sensing control with torque limiting and pressure compensator override ROTARY SERVO CONTROL The rotary servo control is mounted on the off-stroke side of the control piston. Servo pressure is connected to the input port of a four-way valve, and to the end of this valve spool. A drilling and orifice connects to the opposite end of the spool. One cylinder port connects to the off stroke end of the control piston, while the other cylinder port connects to the on stroke end of the control piston, through the control on the opposite side. A rotatable shaft converts to a linear motion on a pin. A sleeve over the pin is driven by a linkage to the control piston. The sleeve/pin combination meters pilot flow from thefour-way valvecontrolling the shifting of the four-way valve, in such a manner that the four-way valve shifts to hold the cylinder position to the corresponding position for the input rotation.

26 CONTROLS HYDRAULIC STROKER In the hydraulic stroker, a spring loaded piston is attached to the pin. A control pressure of 0 psi,, bar causes the piston to commence to move against the spring, to position the pin in proportion to the control pressure, and thus cause the pump to stroke in proportion to control pressure. Full stroke is achieved at 7 psi, 9 bar. ELECTRIC STROKER 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. For a volt coil, the pump commences to stroke at approximately 7 ma electrical signal, and will be at full stroke at approximately 0 ma. PRESSURE COMPENSATOR AND TORQUE LIMITER OVERRIDE 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 the control valve on the opposite side, 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 rotary servo, hydraulic or electric stroker command and reduce stroke according to the compensator or torque limiter setting. Override pressure must be sufficient to overcome servo pressure acting on the larger diameter piston. TIGHTENING TORQUE FOR HYDRAULIC PLUGS PORT SIZE ft-lbs Nm SAE- SAE-6 8 SAE SAE SAE- 0 7 SAE- 0 9 / BSPP 8 /8 BSPP 8 / BSPP 9 6 -/ BSP PORT SIZES...DESCRIPTION...P6 C MOD P60 C MOD PORT C...OFF-STROKE CYL. GAGE...SAE / BSPP PORT C...ON-STROKE CYL. GAGE...SAE / BSPP PORT D...CASE DRAIN...SAE / BSPP PORT D...CASE DRAIN...SAE / BSPP PORT DG...DRAIN GAGE, AIR BLEED PORT...SAE / BSPP PORT AG...INLET GAGE...SAE / BSPP PORT BG...SYSTEM GAGE...SAE / BSPP PORT BG...ALT. SYS. GAGE...SAE / BSPP PORT E...ELECTROHYDRAULIC STROKER SERVO SUPPLY...SAE / BSPP PORT H...HYDRAULIC STROKER SIGNAL...SAE / BSPP PORT LS...LOAD SENSING LINE...SAE / BSPP PORT V...COMPENSATOR, TORQUE LIMITER, LOAD SENSING VENT...SAE /8 BSPP PORT V...OVERRIDE COMP, OVERRIDE TORQUE LIMITER VENT...SAE / BSPP PORT V...SERVO VENT...SAE / BSPP PORT X...SERVO SUPPLY...SAE /8 BSPP PORT XG...SERVO GAGE...SAE / BSPP 6

27 PRESSURE COMPENSATOR CONTROL CCW ROTATION CW ROTATION ITEMS NOT SHOWN C0, C0 C0, C80 PRESSURE COMPENSATOR parts list P6 P60 QTY. ITEM DESCRIPTION PART NO. PART NO. C0, C0 C0, C80 Max. Vol. Stop (Fig. 7) S-98 S-98 Max Vol. Handwheel (Fig. 8) S-9 S-9 *Compensator Control (Fig. 6) S- S- - Buck Up Cap (Fig. 9) S-6 S-6 Screw-H.H.C.,M x 60 mm Screw-H.H.C., M x 80 mm Control Piston O-Ring, 90 S- ARP O-Ring, 70 S- ARP Piston Ring *Include items (Maximum Volume Stop),,, 7 and 8 7

28 PRESSURE COMPENSATOR CONTROL COMPENSATOR DISASSEMBLY. See Figure 6. Back off max. volume screw or handwheel to full displacement. Remove max. volume screw or hand wheel assembly.. Remove bolts holding cap to pump.. Remove plug () and attached parts. Remove spring () and spool (8).. Remove adjusting plug () and attached parts. Remove seal piston (). Note: a 0- screw may be used to assist in pulling the piston. Remove spring (7) and cone (8).. Do not remove sleeve in body (). Sleeve is pressed into cap and finished to size. If sleeve or cap is worn, replace the cap-sleeve assembly (). 6. Examine seat (0) for wear. Do not remove unless damaged. ASSEMBLY See page 6 for tightening torque on plugs. Install Avseal plugs (9) and orifice (9) in body.. Press seat (0) into bore squarely against shoulder in bore.. Install spool (8) into bore as shown. Install spring () over end of spool. Install O-ring (6) on seal piston (6). Lubricate and install into plug (). Install plug () into cap. Install screw (), nut () and plastic cap (7).. Install O-ring (6) on seal piston ().. Lubricate O-ring and install cone (8), spring (7) and seal piston into bore in cap (), being careful that cone enters seat (0). Install remaining parts. Torque plugs () and () 6. Note proper location for cap on pump (pg. ). 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 7 lbs. ft., 0 Nm. 8

29 PRESSURE COMPENSATOR CONTROL SYSTEM PRESSURE PORT C COMPENSATOR ADJUSTMENT VENT CONN. V DIFFERENTIAL ADJUSTMENT FIGURE 6 PARTS LIST FOR FIGURE 6 P6 code C0, C0 S- P60 code C0, C0, S- P6 P60 ITEM DESCRIPTION PART NO. QTY. PART NO. QTY. Cap-Sleeve Assembly S-880 S-88 Adj. Plug Soc. Setscrew /6- x Nut, / Seal Piston O-Ring, 90 S- ARP Spring Cone Avseal Plug Seat Spring Plug, SAE-0, / BSPP O-Ring, 90 S- ARP O-Ring, 90 S- ARP Plug Seal Piston Cap Spool Orifice Plug Plug, SAE-8, /8 BSPP O-Ring, 90 S- ARP Soc. Setscrew /6- x -/ Acorn Nut Plug,SAE-, / BSPP O-ring, 90 S- ARP

30 MAXIMUM VOLUME STOP PARTS LIST FOR FIGURE 7 max. volume stop S-98 ITEM DESCRIPTION PART NO. QTY. Plug, SAE O-Ring, 90 S- ARP Nut, / -0UNC Hex Screw, Soc. Set / 0 x -60 O-Ring,70 S- ARP Figure 7 max. volume stop PARTS LIST FOR FIGURE 8 handwheel S-9 ITEM DESCRIPTION PART NO. QTY. Bracket 0-96 Screw 0-9 Nut, Hex /-6 UNC -000 Handwheel 0-99 Nut, Elastic Stop / O-Ring, 90 S- ARP O-Ring, 90 S- ARP Ball Ball Seat 0-9 Figure 8 Handwheel maximum volume stop MAXIMUM VOLUME HANDWHEEL DISASSEMBLY. See Fig. 8. Remove the two screws holding the bracket () to the control cap.. Turn the handwheel counter-clockwise to remove the stop screw from the control cap.. Remove nut () and handwheel () from the stop screw ().. Remove nut (). Screw () may now be slipped through the bracket () to examine parts and to replace O-ring (6).. Seat (0) pivots and rotates on ball (8) and is retained by pressing two balls (9) into screw (). Replace assembly if damaged. ASSEMBLY. Install ball (8) and seat (0) in screw ().. Press balls (9) into screw () to retain seat. Install O-ring (6) on screw (). Lubricate O-ring and slide screw into bracket (). Install remaining parts.. Turn handwheel clockwise into cap till the screw contacts the control piston.. Install and torque the assembly screws to 7 ft-lb, 0 Nm. 0

31 BUCK-UP CAP FIGURE 9 Buck-up cap assembly BUCK-UP CAP DISASSEMBLY. See Figure 9. Set maximum volume stop to full stroke. Remove screws holding cap to pump. Caution! Spring load could cause injury!. Remove cap assembly from pump.. Remove and examine springs (), () and piston (). If sleeve () is worn, press it out and replace. ASSEMBLY PARTS LIST FOR FIGURE 9 buck-up cap S-6 ITEM DESCRIPTION PART NO. QTY. Piston -68 Spring 0-9 Spring 0-96 Sleeve 0-97 Control Cap O-Ring Plug, SAE Avseal Plug Install Avseal plug (8) into cap. Press sleeve () into cap to shoulder. Install piston (), O-ring (6) and plug (7) into cap.. Install O-rings on interface between cap and pump control pad. Install spring () and spring () into control piston. Install cap assembly on pump housing as indicated on page 7 Fig., guiding the control piston into the bore.. Torque the assembly bolts to 7 ft-lb, 0 Nm. Torque plug (7) to lb-ft, 0 Nm.

32 TORQUE LIMITER CONTROL CCW ROTATION CW ROTATION ITEMS NOT SHOWN J0* K0* TORQUE LIMITER J0** K0** PARTS LIST torque limiter P6 P60 QUANTITY ITEM DESCRIPTION PART NO PART NO. J0* K0* J0**K0** Maximum Volume Stop (Fig. 7) S-98 S-98 Max Vol. Handwheel (Fig. 8) S-9 S-9 ***Low Torque Limiter (Fig. ) S- S- - ***High Torque Limiter (Fig. ) S- S-6 - Buck Up Cap (Fig. 9) S-6 S-6 Screw-H.H.C., M x 60 mm Screw-H.H.C., M x 80 mm Control Piston O-Ring, 90 S- ARP O-Ring, 70 S- ARP Piston ring * Also J0, K0 **Also J80, K80 ***Include items (Maximum Volume Stop),,, 7 and 8

33 TORQUE LIMITER CONTROL PARTS LIST FOR FIGURE 0 P6 torque limiter cap S-9 P60 torque limiter cap S-9 FIGURE 0 Torque limiter cap P6 P60 ITEM DESCRIPTION PART NO. QTY. PART NO. QTY Cap-Sleeve Assembly S-9 S-9 Adj. Plug Soc. Setscrew /6- x Nut, / Seal Piston O-Ring, 90 S- ARP Spring Cone Avseal Plug Seat Spring Plug- SAE-0, / BSPP O-Ring, 90 S- ARP O-Ring, 90 S- ARP Plug Seal Piston Cap Spool Orifice Plug- SAE-8, /8 BSPP O-ring, 70 S- ARP Soc. Setscrew /6- x -/ Nut, Acorn / O-Ring, 70 S- ARP Plug - SAE-, / BSPP O-ring 90 S- ARP

34 TORQUE LIMITER CONTROL 0 Nm 0 Nm torque ft-lb 6,8 Nm Loctite Loctite hydraulic sealant FIGURE Torque Limiter PARTS LIST FOR FIGURE P6 code J0,J0, S- P6 code K0, K0, S- P60 code J0,, J0, S- P60 code K0, K0, S-6 P6 P60 QTY. ITEM DESCRIPTION PART NO. PART NO. J K Cap (Figure 0) S-9 S-9 Screw Clevis pin Spring, Compression Plug, Avseal Screw Nut, Hex Jam /-0 UNC Hex Nut, /-6 UNF Plug, SAE O-Ring, 90 S- ARP Screw, Primary Adjust Body assembly S-96 S-96 7 Outer Spring J Version Outer Spring K Version Inner Spring J Version Inner Spring K Version Spring Retainer Spool O-ring, 70 S- ARP Plug, SAE O-Ring, 90 S- ARP Sleeve Arm assembly S-0 S-0 9 O-Ring, 70 S- ARP Dowel Pin, /8 Dia. x.7 Lg Screw, SHC 0- x / Nut O-Ring, 70 S- ARP

35 TORQUE LIMITER CONTROL DISASSEMBLY. See Figure. Remove screws holding torque limiter body (6) to cap assembly ().. Remove all parts from torque limiter body (6) except pin (0) and arm assembly (8). It is not necessary to remove these parts unless broken or worn. Examine parts for wear or damage.. Remove screw (). Examine head for excessive wear, and body for smooth sealing surface with O-ring.. Remove maximum stop handwheel assembly or maximum stop screw assembly.. Remove cap assembly (). 6. See Figure 0. Remove plug () and attached parts. Remove spring () and spool (8). 7. Remove adjusting plug () and attached parts. Remove spring (7) and cone (8). 8. Do not remove sleeve in body (). Sleeve is pressed into cap and finished to size. If sleeve or cap is worn, replace the cap-sleeve assembly (). 9. Examine seat (0) for wear. Do not remove unless damaged. ASSEMBLY See page 6 for tightening torque on plugs. See Figure 0. Install Avseal plugs (9) and orifice (9) in body.. Press seat (0) into bore squarely against shoulder in bore.. Install spool (8) into bore as shown. Install spring () over end of spool. Install O-ring (6) on seal piston (6). Lubricate and install into plug (). Install plug () into cap. Install screw (), nut () and acorn nut (7). Install plug (). Torque plugs to 7 lb. ft., 0 Nm. Install plug (). Torque to 6 lb. ft., 6 Nm. Install plug (8). Torque to lb. ft., Nm.. Install O-ring (6) on seal piston (). Lubricate O-ring and Install cone (8), spring (7) and seal piston () into bore in cap (), being careful that cone enters seat (0). Install adj. plug (), screw (), nut () and acorn nut (6).. Carefully install O-ring (7) in the cap. 6. Note proper location for control cap (pg. ). Install O-rings on interface between cap and pump control pad. Install cap, guiding control piston into bore. Torque mounting screws to 7 lb. ft., 0 Nm. 7. Install maximum volume handwheel or screw assembly. Set stop to clear control piston. 8. See Figure. Apply Loctite on threads of screw (), lubricate the shank, thread through the cap into the control piston, and torque to lb. ft., 6,8 Nm 9. Measure height from control cap to top of screw. With control piston at full stroke, dimension must be.0 +/-.0 in., 8, +/- 0,76 mm. 0.Press dowel (0) into body (6), through the link assembly (8), to /, 6, mm below surface. Apply Loctite hydraulic sealant to threads of screws () and install over dowel (0).. While sleeve (7) is engaged into dowel on link (8), slide spool () into bore of body (6), and through sleeve (7). Spool () must move freely and easily at all positions of the link (8).. Assemble remaining parts per drawing. While spring retainer is engaging clevis pin () under dowel of link (8), slide the other opening of spring retainer over the top of the screw (). Attach body assembly (6) to cap () and torque screws to 7 lb. ft., 0 Nm. system pressure 9 port C vent connection V 7 6 compensator adjustment 6 6 differential adjustment Ref. Figure 0 Torque limiter cap