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Denison Hydraulics Premier Series Service Information

Open circuit pump control
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DENISON HYDRAULICS
Premier Series
open circuit pump controls
P16 B-mod, P09 A-mod
service information
Publ. S1-AM026-A replaces S1-AM026
Internet: http://www.denisonhydraulics.com E-mail: denison@denisonhydraulics.com
www.comoso.com

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  • Page 1 DENISON HYDRAULICS Premier Series open circuit pump controls P16 B-mod, P09 A-mod service information Publ. S1-AM026-A replaces S1-AM026 Internet: http://www.denisonhydraulics.com E-mail: 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

    CHARACTERISTICS TYPICAL CHARACTERISTICS Specification Term • compensator response off-stroke sec. 0.070* 0.100* on-stroke sec. 0.140* 0,150* (per SAE J745 Apr. 87 at 5000 psi, 345 bar) • compensator adjustment psi/turn 2000 2000 bar/turn • minimum compensating pressure 200** 200** (comp, load sensing, torque limiter) 13,6** 13,6** •...

  • Page 4: Introduction

    INTRODUCTION 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.

  • Page 5: Electric Stroker

    INTRODUCTION pump to stroke in proportion to control pressure. Full stroke is achieved at 230 psi, 16 bar, (P09), and 275 psi, 19 bar (P16). By mounting an electrically modulated pressure control valve on the hydraulic stroker ELECTRIC STROKER to establish the control pressure, pump stroke is controlled by an electrical signal. At approximately 125 mA electrical signal, the pump commences to stroke, and at approximately 315 mA, (P09) and 335 mA, (P16), the pump will be at full stroke.

  • Page 6: Pressure Compensator Parts List

    PRESSURE COMPENSATOR CCW ROTATION CW ROTATION ITEMS 6 7 8 9 NOT SHOWN PRESSURE COMPENSATOR QTY. parts list ITEM DESCRIPTION PART NO. PART NO. Max. Vol. Stop (Fig. 1) S22-12983 S22-12983 — Max Vol. Handwheel (Fig. 2) S22-12915 S22-12915 — Compensator Control (Fig.
  • Page 7 PRESSURE COMPENSATOR PARTS LIST FOR FIGURE 1, MAX. VOL. STOP S22-12983 ITEM DESCRIPTION PART NO. QTY. Plug 10HP5N-S 488-35055 O-Ring, 90 S-1 ARP 910 691-00910 Nut, 3/4 -10UNC Hex 031-91049 Screw, Soc. Set 3/4 10 x 3 311-26320 O-Ring,70 S -1 ARP 118 671- 00118 FIGURE 1 MAXIMUM VOLUME STOP...

  • 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 FIGURE 3 COMPENSATOR SYSTEM PRESS. 11 21 SAE-10 ST. THD PORT TORQUE 75 FT-LB, C1, SAE-4 102 Nm VENT CONN. “V” ST. THD DIFFERENTIAL SAE-8 ST. THD. TORQUE ADJUSTMENT TORQUE 46 FT-LB, 11 FT-LB, 62 Nm 15 Nm PARTS LIST FOR FIGURE 3 ITEM...

  • Page 10: Buck-Up Cap Disassembly, Assembly

    PRESSURE COMPENSATOR FIGURE 4 BUCK-UP CAP TORQUE TORQUE 140 LB-FT 225 LB-FT 190 Nm 305 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.

  • Page 11: Electric Stroker Parts List

    ELECTRIC STROKER 3 5 6 3 5 6 3 5 6 NOT SHOWN CCW ROTATION 3 5 6 3 5 6 3 5 6 10 11 12 13 14 8 NOT SHOWN NOT SHOWN E1J – E1K CW ROTATION ELECTRIC STROKER QUANTITY parts list ITEM DESCRIPTION...

  • 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 5. Adjust amperage (100-150 mA) to give 50 PSI, 34,5 bar reading on the propor- tional valve gage port. Back out zero screw (24) and adjust screw (9) until output flow is at zero stroke position. Lock both adjustments in place. 6.

  • Page 14: Parts Lists For Figure 5 And Figure

    ELECTRIC STROKER PARTS LIST FOR FIGURE 5 ITEM DESCRIPTION PART NO. QTY. Cap (Figure 6) S22-15262 electric stroker S22-15305 Orifice 032-92399 Screw 032-91461 O-Ring, 70 S -1 ARP 010 671-00010 Clevis pin 321-40000 Spring, Compression 032-92100 Plug, Avseal 447-00026 Nut, 5/16-24 335-13100 Soc.

  • 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 TORQUE 75 LB • 102 Nm HIGH FLOW PRESSURE ADJUST. LOCTITE 242 TORQUE 5 LB. • 6,78 N m HIGH PRESSURE FLOW ADJUST. TORQUE 46 LB • 62 Nm FIGURE 8 TORQUE LIMITER OVERRIDE QTY. PARTS LIST FOR FIGURE 8 ITEM DESCRIPTION PART NO.
  • Page 18 TORQUE LIMITER OVERRIDE SYSTEM PRESS. SAE-10 TORQUE 75 LB-FT, 102 Nm PORT C1, SAE-4 ST. THD TORQUE 11 FT-LB, 15 Nm SERVO PRESSURE FROM OPPOSITE SIDE SAE-6 STR. THD. VENT CONN. “V” SAE-8 ST. THD. TORQUE 46 FT-LB, 62 Nm COMP.

  • Page 19: Torque Limiter Override Test And Adjustment

    TORQUE LIMITER OVERRIDE TORQUE LIMITER OVERRIDE 1. Install gages on system pressure and on compensator vent ports. 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 12, 13, 19, 20, 24). 3. Remove cap assembly. 4. Remove plug (15) and attached parts. Remove spring (11) and spool (18). 5.
  • Page 21 COMPENSATOR OVERRIDE SYSTEM PRESS. TORQUE SAE-10 ST. THD 75 FT-LB, 102 Nm PORT C1, SAE-4 ST. THD TORQUE 11 FT-LB, 15 Nm TORQUE 75 FT-LB, 102 Nm COMP. VENT CONN. “V” ADJUSTMENT SAE-8 ST. THD. TORQUE 46 FT-LB, 62 Nm DIFFERENTIAL ADJUSTMENT FIGURE 10...

  • Page 22: Hydraulic Stroker Parts List

    HYDRAULIC STROKER 3 5 6 3 5 6 3 5 6 8 NOT SHOWN CCW ROTATION 3 5 6 3 5 6 3 5 6 10 11 12 13 14 NOT SHOWN 8 NOT SHOWN H1J – H1K CW ROTATION HYDRAULIC STROKER QUANTITY parts list...

  • 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 nec- essary to remove these parts unless broken or worn. Examine parts for wear or damage. 3.
  • Page 24 HYDRAULIC STROKER TORQUE 75 LB • 102 Nm ADJUST FOR ZERO FLOW AT 50 PSI, 3,45 BAR SIGNAL PRESSURE PORT “H” SIGNAL PORT SAE-4 STR THD. PORT “X” SAE-6 STR THD. SERVO INLET TORQUE 5 FT-LB, 6,8 Nm LOCTITE 242 FIGURE 11 LOCTITE 242 HYDRAULIC STROKER...

  • Page 25: Torque Limiter Parts List

    TORQUE LIMITER CCW ROTATION J10 – K10 J20 – K20 CW ROTATION TORQUE LIMITER PARTS LIST QUANTITY torque limiter ITEM DESCRIPTION PART NO PART NO. J10 Max. Vol. Stop (Fig. 1) S22-12983 S22-12983 — — Max Vol. Handwheel (Fig. 2) S22-12915 S22-12915 —...

  • Page 26: Torque Limiter Disassembly & Assembly

    TORQUE LIMITER TORQUE LIMITER 1. See Figure 12. Remove 2 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 HIGH FLOW PRESSURE ADJUST. TORQUE 46 LB • FT HIGH PRESSURE 62 Nm FLOW ADJUST. FIGURE 12 – TORQUE LIMITER ASSEMBLY SYSTEM PRESS. TORQUE SAE-10 ST. THD 75 FT-LB, 102 Nm PORT C1, SAE-4 ST. THD TORQUE 11 FT-LB, 15 Nm VENT CONN.

  • Page 28: Parts Lists For Figure 12 And Figure

    TORQUE LIMITER PARTS LIST FOR FIG. 12 QTY. P09 code J, S22-15732 ITEM DESCRIPTION PART NO. PART NO. P09 code K, S22-15313 Cap (Figure 9) S22-12913 S22-12913 P16 code J, S22-15313 Screw 032-91461 032-91461 Clevis pin 321-40000 321-40000 P16 code K, S22-15315 Spring, Compression 032-92100 032-92100...

  • Page 29: Torque Limiter Test And Adjustment

    TORQUE LIMITER TORQUE LIMITER TEST AND 1. Install gages on system pressure and on compensator vent ports. 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 3 5 6 3 5 6 3 5 6 8 NOT SHOWN CCW ROTATION 3 5 6 3 5 6 3 5 6 10 11 12 13 14 NOT SHOWN 8 NOT SHOWN R1J – R1K CW ROTATION PARTS LIST QUANTITY rotary servo...

  • 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 PORT “X” SAE-6 STR. THD. SERVO INLET TORQUE 75 LB • 102 Nm SET (9) FOR FULL FLOW WITH SHAFT (10) FULLY CLOCKWISE. LOCK IN POSITION WITH NUT (8). LOCTITE 242 FIGURE 14 ROTARY SERVO PARTS LIST FOR FIGURE 14 ITEM DESCRIPTION PART NO.

  • Page 33: Load Sensing Control Parts List

    LOAD SENSING CONTROL CCW ROTATION CW ROTATION 9 10 9 10 NOT SHOWN NOT SHOWN LOAD SENSING CONTROL QTY. ITEM DESCRIPTION PART NO. PART NO. parts list Max. Vol. Stop (Fig. 1) S22-12983 S22-12983 — Max Vol. Handwheel (Fig. 2) S22-12915 S22-12915 —...

  • 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. volume 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 TORQUE system pressure 75 LB • SAE-10 st. thd. 102 Nm torque 75 ft-lb, 102 Nm “C1” gage port SAE-4 st. thd. torque 11 ft-lb, 15 Nm “V” vent port SAE-8 st. thd. torque 46 ft-lb, 62 Nm compensator adjustment differential adjustment “LS”...

  • Page 36: Hydraulic Circuits

    HYDRAULIC CIRCUITS HYDRAULIC CIRCUIT PRESSURE COMPENSATOR HYDRAULIC CIRCUIT PRESSURE COMPENSATOR, load sensing configuration HYDRAULIC CIRCUIT TORQUE LIMITER www.comoso.com...

  • Page 37: Manual Rotary Servo

    HYDRAULIC CIRCUITS HYDRAULIC CIRCUIT ROTARY SERVO HYDRAULIC CIRCUIT ROTARY SERVO WITH COMPENSATOR OVERRIDE HYDRAULIC CIRCUIT ROTARY SERVO WITH TORQUE LIMITER OVERRIDE www.comoso.com...

  • Page 38: Electric Stroker

    HYDRAULIC CIRCUITS HYDRAULIC CIRCUIT ELECTRIC STROKER HYDRAULIC CIRCUIT ELECTRIC STROKER WITH COMPENSATOR OVERRIDE HYDRAULIC CIRCUIT ELECTRIC STROKER WITH TORQUE LIMITER OVERRIDE www.comoso.com...

  • Page 39: Hydraulic Stroker

    HYDRAULIC CIRCUITS HYDRAULIC CIRCUIT HYDRAULIC STROKER HYDRAULIC CIRCUIT HYDRAULIC STROKER WITH COMPENSATOR OVERRIDE HYDRAULIC CIRCUIT HYDRAULIC STROKER WITH TORQUE LIMITER OVERRIDE www.comoso.com...

  • Page 40: Load Sensing Control

    HYDRAULIC CIRCUITS & HYDRAULIC STROKER PERFORMANCE HYDRAULIC CIRCUIT LOAD SENSING CONTROL HYDRAULIC STROKER PERFORMANCE - P09 CONTROL PRESSURE, BAR CONTROL PRESSURE, PSI HYDRAULIC STROKER PERFORMANCE - P16 CONTROL PRESSURE, PSI CONTROL PRESSURE, BAR www.comoso.com...

  • Page 41: Stroker Performance

    ELECTROHYDRAULIC STROKER PERFORMANCE ELECTROHYDRAULIC STROKER PERFORMANCE P09, 24 VOLT 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 ELECTROHYDRAULIC STROKER PERFORMANCE P09, 12 VOLT 250 300 350 400 450 500 550 600 650 700 250 300 350 400 450 500 550 600 650 700 CONTROL SIGNAL, mA...

  • Page 42: Fluid Connections

    FLUID CONNECTIONS FLUID CONNECTIONS • port A (inlet) 3-1/2 SAE code 61 3000 psi, 209 bars split flange 76.2 88.9 • port B (system) 1 1/2 1 1/2 SAE code 62 7250 psi, 505 bars split flange 38.1 38.1 • port C1, C2 (cylinder gage ports) •...

  • Page 43: Installation Drawings

    P09 PUMP INSTALLATION DRAWINGS • COMPENSATOR WITH ADJ. MAX. VOLUME SCREW STOP - C1* COMPENSATOR VENT CONN. INLET PRESSURE 0.77 OR COMPENSATOR WITH HANDWHEEL ADJ.MAX.VOLUME - C2* CASE DRAIN (CCW ROTATION SHOWN) GAUGE CONNECTION (19.4) GAUGE CONNECTION SAE-8 STD. THREAD SAE-4 STD.
  • Page 44 P16 PUMP INSTALLATION DRAWINGS • COMPENSATOR WITH ADJ. MAX. VOLUME SCREW STOP-C1* 2.97 OR COMPENSATOR WITH HANDWHEEL ADJ. MAX. VOLUME STOP-C2* 2.90 18.75 REF. "DG" REF. REF. "AG" 75,4 (476,3) FAR SIDE 73,7 REF. "V" FAR SIDE 16.17 (CCW ROTATION .437 (410,84) (87,3)
  • Page 45 www.comoso.com...
  • Page 46 www.comoso.com...
  • Page 47 www.comoso.com...
  • Page 48 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 49: Controls Key Sheet

    CONTROLS KEY SHEET P16 - * * 1 B - C 1 0 - * Secondary control options O-S22-15256– None P-S22-15530 – Compensator Override J-(see below)Low Torque Limiter Override K-(see below) High Torque Limiter Override Primary control options 1-S22-12983 – Standard maximum volume screw 2-S22-12915 –...
  • Page 50 SALES & SERVICE WORLDWIDE International Distributors Australia France Mexico, Central America, South In Europe: DENISON HYDRAULICS Pty. Ltd. DENISON HYDRAULICS America and Caribbean Cyprus 41-43 St. Hillers Road FRANCE SA Countries Contact Eastern Europe P.O. Box 192 14, route du Bois Blanc DENISON HYDRAULICS Inc.

This manual is also suitable for:

P16 b-modP09 a-mod

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