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Denison Hydraulics Premier Series Service Information

Open loop pump control
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DENISON HYDRAULICS
Premier Series
P05 open loop pump controls
service information
Publ. S1-AM028
Internet: http://www.denisonhydraulics.com E-mail: denison@ denisonhydraulics.com
www.comoso.com

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Summary of Contents for Denison Hydraulics Premier Series

  • Page 1 DENISON HYDRAULICS Premier Series P05 open loop pump controls service information Publ. S1-AM028 Internet: http://www.denisonhydraulics.com E-mail: denison@ denisonhydraulics.com www.comoso.com...

  • Page 2: Table Of Contents

    CONTENTS PAGE 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 &...

  • Page 3: Typical Characteristics

    • electric stroker control amps 12V) 0 disp. full disp. pulse width modulation frequency: 100-150 Denison Hydraulics electric stroker accessories mating connector: Din 43650 type AF part no. 167-10008-8 (provided) Jupiter driver S20-14078 Jupiter power supply S20-11715 Options card S20-ll716 Venus controller 020-14103 •...

  • Page 4: Introduction

    INTRODUCTION GENERAL The instructions contained in this manual cover complete disassembly and reassembly of the con- trols. Before proceeding with the disassembly or reassembly of any unit, this manual should be studied in order to become familiar with proper order and parts nomenclature. DESCRIPTION OF OPERATION A piloted three-way valve spool and sleeve combination is the nucleus of the control function.

  • Page 5: Electric Stroker

    INTRODUCTION 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. At approximately 125 mA electrical signal, the pump commences to stroke, and at approximately 290 mA, the pump will be at full stroke.

  • Page 6: Pressure Compensator Parts List

    PRESSURE COMPENSATOR CCW ROTATION CW ROTATION ITEMS NOT SHOWN QTY. PRESSURE COMPENSATOR ITEM DESCRIPTION PART NO. Max. Vol. Stop (Fig. 1) S22-15467 — parts list Max Vol. Handwheel (Fig. 2) S22-15448 — Compensator Control (Fig. 3) S22-15394 — Compensator Control S22-15626 —...
  • Page 7 PRESSURE COMPENSATOR PARTS LIST FOR FIGURE 1, MAX. VOL. STOP S22-15467 ITEM DESCRIPTION PART NO. QTY. Plug 8HP5N-S 488-35018 O-Ring, 90 S-1 ARP 908 691-00908 Nut, M16 Hex 032-91822 Screw, Soc. Set 311-50001 O-Ring,70 S -1 ARP 115 671- 00115 FIGURE 1 MAXIMUM VOLUME STOP MAXIMUM VOLUME HANDWHEEL...

  • Page 8: Compensator Disassembly, Assembly, Test

    PRESSURE COMPENSATOR COMPENSATOR DISASSEMBLY 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.
  • Page 9 PRESSURE COMPENSATOR compensator adjustment differential adjustment port “V” compensator vent SAE-8 FIGURE 3 torque 50 ft-lb., COMPENSATOR 68 Nm port “C2” control press. port SAE-4 torque 11 ft- lb., 15 Nm system pressure port SAE-10, torque 90 ft- lb., 122 Nm PARTS LIST FOR FIGURE 3 ITEM DESCRIPTION...

  • Page 10: Buck-Up Cap Disassembly, Assembly

    PRESSURE COMPENSATOR FIGURE 4 BUCK-UP CAP TORQUE 140 FT- LB, 190 Nm BUCK-UP CAP DISASSEMBLY 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.

  • Page 11: Electric Stroker Parts List

    ELECTRIC STROKER NOT SHOWN CCW ROTATION NOT SHOWN E1J, E1K CW ROTATION NOT SHOWN ELECTRIC STROKER QUANTITY ITEM DESCRIPTION PART NO. E10 E1J E1K E1P parts list Electric Stroker (Fig. 5) S22-15399 Control Cap (Fig. 7) S22-15325 — — — Low Torque Override (Fig.

  • Page 12: Electric Stroker Disassembly, Assembly, Test

    ELECTRIC STROKER ELECTRIC STROKER 1. See Figure 5. Remove 3 screws (37) holding block (36) to body (16). DISASSEMBLY 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.
  • Page 13 ELECTRIC STROKER 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 290 mA. Pump should go to full stroke. Set max. volume screw on opposite control cap for full stroke.

  • Page 14: Parts Lists For Figure 5 And Figure

    ELECTRIC STROKER PARTS LIST FOR FIGURE 5 ITEM DESCRIPTION PART NO. QTY. electric stroker S22-15399 Cap (Figure 6) S22-15327 Screw 032-91461 Clevis pin 321-40000 Spring, Compression 032-92100 Plug, Avseal 447-00026 Nut, 5/16-24 335-13100 Soc. Setscrew, 5/16-24 x 1-1/4 312-13180 Seal Piston 032-91918 O-Ring, 90 S-1 ARP 012 691-00012...

  • Page 15: Control Cap Disassembly, Assembly

    ELECTRIC STROKER CONTROL CAP DISASSEMBLY 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. ASSEMBLY 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.

  • Page 16: Torque Limiter Override Disassembly & Assembly

    TORQUE LIMITER OVERRIDE TORQUE LIMITER OVERRIDE 1. See figure 8. Remove 2 screws holding torque limiter body (16) to cap assembly DISASSEMBLY (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.
  • Page 17 TORQUE LIMITER OVERRIDE high pressure flow high flow pressure adjustment adjustment torque 50 ft-lb, 68 Nm Loctite hyd. sealant loctite 242 torque 5 ft-lb, 6,8 Nm FIGURE 8 TORQUE LIMITER OVERRIDE differential adjustment compensator adjustment port “V” compensator vent, SAE-8 torque 50 ft-lb., 68 Nm port “C1”...

  • Page 18: Parts Lists For Figure 8 And Figure

    TORQUE LIMITER OVERRIDE QTY. PARTS LIST FOR FIGURE 8 ITEM DESCRIPTION PART NO. torque limiter override Cap (Figure 9) S22-15412 code J S22-15405 Screw 032-91461 code K S22-15630 Clevis pin 321-40000 Spring, Compression 032-92100 Plug, Avseal 447-00026 Screw 032-91445 Nut, Hex Jam 1/4-20 UNC 340-00038 Hex Nut, 3/4-16 UNF 032-91449...

  • Page 19: Torque Limiter Override Test And Adjustment

    TORQUE LIMITER OVERRIDE TORQUE LIMITER OVERRIDE 1. Install gages on system pressure and on compensator vent port “V”. TEST AND ADJUSTMENT 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.

  • Page 20: Compensator Override Disassembly, Assembly, Test

    COMPENSATOR OVERRIDE COMPENSATOR OVERRIDE 1. See Figure 10. Remove tube line to cap. DISASSEMBLY 2. Remove maximum volume stop assembly (items 20, 21, 22, 23, 24). 3. Remove cap assembly. 4. Remove plug (15) and attached parts. Remove spring (11) and spool (18). 5.
  • Page 21 COMPENSATOR OVERRIDE differential compensator adjustment adjustment port “V” vent conn. SAE-8 torque 50 ft-lb, 68 servo pressure torque 50 ft-lb., from opposite 68 Nm cap, SAE-6 port “C1” cylinder pressure port SAE -4, torque 11 ft-lb., 15 Nm system pressure FIGURE 10 SAE-10 COMPENSATOR OVERRIDE CONTROL...

  • Page 22: Hydraulic Stroker Parts List

    HYDRAULIC STROKER NOT SHOWN CCW ROTATION NOT SHOWN H1J, H1K CW ROTATION NOT SHOWN HYDRAULIC STROKER QUANTITY parts list ITEM DESCRIPTION PART NO. H10 H1J H1K H1P Hydraulic Stroker (Fig. 11) S22-15400 Control Cap (Fig. 7) S22-15325 — — — Low Torque Override (Fig.

  • Page 23: Hydraulic Stroker Disassembly, Assembly, Test

    HYDRAULIC STROKER HYDRAULIC STROKER 1. See figure 11. Remove 2 screws holding body (16) to cap assembly (1). DISASSEMBLY 2. 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.
  • Page 24 HYDRAULIC STROKER port “H” control signal inlet, SAE-4 Loctite 242 torque 5 ft-lb., 6,8 Nm Loctite port “C2” cyl. press. SAE-4 torque 50 ft- torque 75 ft.lb., lb., 68 Nm 102 Nm port “X” FIGURE 11 servo supply HYDRAULIC STROKER SAE-6 PARTS LIST FOR FIGURE 11 ITEM DESCRIPTION...

  • Page 25: Torque Limiter Parts List

    TORQUE LIMITER NOT SHOWN CCW ROTATION CW ROTATION NOT SHOWN J/K10 J/K20 ITEMS NOT SHOWN QUANTITY PARTS LIST ITEM DESCRIPTION PART NO. J10 torque limiter Max. Vol. Stop (Fig. 1) S22-15467 — — Max Vol. Handwheel (Fig. 2) S22-15448 — —...

  • Page 26: Torque Limiter Disassembly & Assembly

    TORQUE LIMITER TORQUE LIMITER 1. See Figure 12. Remove two screws holding torque limiter body (16) to cap assem- bly (1). DISASSEMBLY 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.
  • Page 27 TORQUE LIMITER Loctite high pressure flow adjustment torque 5 ft.lb., 6.8 Nm high flow pressure adjustment Loctite hyd. sealant torque 75 ft-lb., 102 Nm FIGURE 12 – TORQUE LIMITER ASSEMBLY compensator adjustment differential adjustment port “V” vent connection SAE-8, torque 50 ft- lb., 68 Nm port “C1”...

  • Page 28: Parts Lists For Figure 12 And Figure

    TORQUE LIMITER PARTS LIST FOR FIG. 12 QTY. code J10, S22-15401 ITEM DESCRIPTION PART NO. code K10, S22-15629 Cap (Figure 13) S22-15407 code J20, S22-15627 Screw 032-91461 Clevis pin 321-40000 code K20, S22-15635 Spring, Compression 032-92100 Plug, Avseal 447-00026 Screw 032-91445 Nut, Hex Jam 1/4-20 UNC 340-00038...

  • Page 29: Torque Limiter Test And Adjustment

    TORQUE LIMITER TORQUE LIMITER TEST AND 1. Install gages on system pressure and on compensator vent port “V”. ADJUSTMENT 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.

  • Page 30: Rotary Servo Parts List

    ROTARY SERVO NOT SHOWN CCW ROTATION NOT SHOWN R1H, R1J CW ROTATION NOT SHOWN PARTS LIST QUANTITY rotary servo ITEM DESCRIPTION PART NO. R10 R1J R1K R1P Rotary Servo (Fig. 14) S22-15403 Control Cap (Fig. 7) S22-15325 — — — Low Torque Override (Fig.

  • Page 31: Rotary Servo Disassembly, Assembly, Test

    ROTARY SERVO ROTARY SERVO 1. See Figure 14. Remove 2 screws holding body (16) to cap assembly (1). DISASSEMBLY 2. 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.
  • Page 32 ROTARY SERVO loctite torque 5 ft-lb., 6.8 Nm Loctite hydraulic sealant max. stroke adjust. port “C2” cylinder pressure torque SAE-4 75 ft-lb., torque 11 ft-lb., 15 102 Nm torque 50 ft-lb., 68 Nm servo connection to opposite cap port “X” SAE-6 servo connection SAE-6...

  • Page 33: Load Sensing Control Parts List

    LOAD SENSING CONTROL CCW ROTATION CW ROTATION ITEMS NOT SHOWN QTY. ITEM DESCRIPTION PART NO. LOAD SENSING CONTROL Max. Vol. Stop (Fig. 1) S22-15467 — parts list Max Vol. Handwheel (Fig. 2) S22-15448 — Load Sensing Control (Fig. 15) *S22-15402 —...

  • Page 34: Load Sensing Control Disassembly, Assembly, Test

    LOAD SENSING CONTROL LOAD SENSING CONTROL 1. See Figure 15 Back off max. volume screw to full displacement. Remove max. vol- ume screw assembly. DISASSEMBLY 2. Remove bolts holding cap to pump. 3. Remove isolation valve (29) from block (28). Remove plug (15) and attached parts. Remove spring (11) and spool (18).
  • Page 35 LOAD SENSING CONTROL port “LS”, SAE-4, connection to load sensing line torque 50 ft-lb., 68 Nm differential adjustment compensator adjustment torque 75 ft-lb., 102 Nm system pressure conn., SAE-10, torque 90 ft-lb, 122 Nm port “V”, vent connection, port “C1” cyl gage port SAE-8, torque 50 ft-lb, SAE-4, torque 11 ft-lb., 15 Nm 68 Nm...

  • Page 36: Hydraulic Circuits

    HYDRAULIC CIRCUITS HYDRAULIC CIRCUIT PRESSURE COMPENSATOR (C1O) HYDRAULIC CIRCUIT PRESSURE COMPENSATOR, LOAD SENSING CONFIGURA- TION (C10) HYDRAULIC CIRCUIT TORQUE LIMITER (J10 & K10) www.comoso.com...

  • Page 37: Manual Rotary Servo

    HYDRAULIC CIRCUITS HYDRAULIC CIRCUIT ROTARY SERVO (R10) HYDRAULIC CIRCUIT ROTARY SERVO WITH COMPENSATOR OVERRIDE (R1P) HYDRAULIC CIRCUIT ROTARY SERVO WITH TORQUE LIMITER OVERRIDE (R1J & R1K) www.comoso.com...

  • Page 38: Electric Stroker

    HYDRAULIC CIRCUITS HYDRAULIC CIRCUIT ELECTRIC STROKER (E10) HYDRAULIC CIRCUIT ELECTRIC STROKER WITH COMPENSATOR OVERRIDE (E1P) HYDRAULIC CIRCUIT ELECTRIC STROKER WITH TORQUE LIMITER OVERRIDE (E1J & E1K) www.comoso.com...

  • Page 39: Hydraulic Stroker

    HYDRAULIC CIRCUITS HYDRAULIC CIRCUIT HYDRAULIC STROKER (H10) HYDRAULIC CIRCUIT HYDRAULIC STROKER WITH COMPENSATOR OVERRIDE (H1P) HYDRAULIC CIRCUIT HYDRAULIC STROKER WITH TORQUE LIMITER OVERRIDE (H1J & H1K) www.comoso.com...

  • Page 40: Load Sensing Control

    HYDRAULIC CIRCUITS, STROKER PERFORMANCE CURVES HYDRAULIC CIRCUIT LOAD SENSING CONTROL (L10) HYDRAULIC STROKER PERFORMANCE CONTROL PRESSURE, BAR CONTROL PRESSURE, PSI ELECTRIC STROKER PERFORMANCE, 24 V. COIL 125 150 175 200 225 250 275 300 325 350 125 150 175 200 225 250 275 300 325 350 CONTROL SIGNAL, mA CONTROL SIGNAL, mA ELECTRIC STROKER...

  • Page 41: Installation Drawings

    INSTALLATION DRAWINGS "V" COMPENSATOR VENT CONNECTION CASE DRAIN "D1" SAE-8 STRAIGHT THREAD SAE-12 STR. THD. "C2" CONTROL CYL. GAGE PORT SAE-4 STRAIGHT THREAD "AG" INLET GAGE CONNECTION .4375 SAE-4 STRAIGHT THREAD .4355 1.75 11.60 SQUARE KEY x 11,112 (44,4) (2,3) (294,6) 11,062 1.19...
  • Page 42 INSTALLATION DRAWINGS PRIMARY SERVO CONTROLS FULL ADJUSTMENT "X" SERVO PRESSURE 5.81 (CCW ROTATION SHOWN) SEE CONTROL LOC. FOR 5.13 1.92 (147,6) PORT SPEC'S (130,2) (48,9) 2.69 ELECTRO-HYDRAULIC STROKER "E1*" (68,3) ZERO VOLUME ADJ. 1.88 ELEC/HYD STROKER (47,8 3.30 CONTROL PORT "E" (83,9) SAE-4 (400-1000 PSI) "C2"...
  • Page 43 INSTALLATION DRAWINGS 5.60 (142,3) SECONDARY SERVO CONTROLS 2.97 2.69 (75.5) MAX. VOLUME ADJUSTMENT (68.3) FOR "E", "H", & "R" PRIMARY CONTROLS ONE (1) FULL TURN = CONTROL LOCATION (CW ROT A TION SHOWN) APPROX. 1/8 STROKE = NINE (9) FULL TURN = FOR CW ROTATION FULL TO ZERO STROKE BUCKDOWN CONTROL CAP "**O"...
  • Page 44 INSTALLATION DRAWINGS MAX. VOLUME HANDWHEEL ADJUSTMENT 2.57 ONE (1) FULL TURN =APPROX. 1/8 STROKE 2.80 (65,2) NINE FULL TURNS =FULL TO ZERO STROKE (71,0) "B" OUTLET PORT MAX. VOLUME SCREW ADJUSTMENT ONE (1) FULL TURN =APPROX. 1/8 STROKE NINE (9) FULL TURNS =FULL TO ZERO STROKE 5.97 (151,8) "C2"...

  • Page 45: Controls Key Sheet

    CONTROLS KEY SHEET P05 - * * 1 * - C 1 0 - * Secondary control options Pre-tested control assembly O-None S22-15325 J-Low Torque Limiter Override 800 - 1500 in-lb., 90 - 170 Nm S22-15405 K-High Torque Limiter Override (over 1500 in-lb., 170 Nm) S22-15630 P-Compensator Override S22-15404...

  • Page 46: Technical Data Conversions

    CONVERSIONS & FORMULAS DEFINITION & UNIT /rev x 16,387 = cm /rev /rev x 0,06102 = in /rev displacement gpm x 3,78 = l/min l/min x 0,2642 = gpm flow hp x 0,7457 = kW kW x 1,341 = hp power lb-ft x 1,3567 = Nm Nm x 0,7376 = lb-ft...
  • Page 47 NOTES www.comoso.com...
  • Page 48 SALES & SERVICE WORLDWIDE International Distributors Australia Germany Singapore In Europe: DENISON HYDRAULICS Pty. Ltd. DENISON HYDRAULIK GmbH DENISON HYDRAULICS S.E.A. Pte. Cyprus 41-43 St. Hillers Road Herderstrasse 26 Ltd. Eastern Europe P.O. Box 192 D-40721 Hilden No. 11 Lorong Tukang Dua The Faroe Islands Auburn, N.S.W.

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