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Denison Hydraulics Goldcup Series Service Information

Closed circuit piston pumps
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DENISON HYDRAULICS
goldcup series
closed circuit piston pumps
P6, P7, P8S
service information
Publ. LT3-00058-2 Replaces S1-AM025-A
Revised 9/02
E-Mail: denison@denisonhydraulics.com
Internet: http://www.denisonhydraulics.com

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  • Page 1 DENISON HYDRAULICS goldcup series closed circuit piston pumps P6, P7, P8S service information Publ. LT3-00058-2 Replaces S1-AM025-A Revised 9/02 E-Mail: denison@denisonhydraulics.com Internet: http://www.denisonhydraulics.com...

  • Page 2: Table Of Contents

    CONTENTS PAGE installation typical characteristics fluid connections general description mounting shaft information piping service information recommended fluids viscosity viscosity index temperature alternate fluids maintenance fluid cleanliness for new installation start-up procedure comparison of solid contamination classification system troubleshooting assembly tool drawings, T1, T2, T3, T4, T5 disassembly rework of wear parts assembly...

  • Page 3: Installation

    INSTALLATION TYPICAL CHARACTERISTICS Specification Term • displacement at max. angle /rev. 6.00 7.25 8.00 /rev (98) (119) (131) • pressure ports A & B max. 5000 5000 3600 continuous (345) (345) (248) max. intermittent 6000 6000 4350 (414) (414) (300) •...
  • Page 4 INSTALLATION port size function 1 1/2" 4 bolt SAE 6000 psi inlet/outlet AG, BG SAE - 6 straight thread system pressure gage, ea. side 1 1/2" 4 bolt SAE 6000 psi outlet/inlet SAE - 16 straight thread internal auxiliary pump inlet D1, D2 SAE - 12 straight thread case drain...

  • Page 5: General

    INSTALLATION GENERAL The DENISON HYDRAULICS Goldcup 6, 7, and 8 axial piston pumps feature advance design concepts which are time proven and provide for advance pumping and control concepts. The instructions contained in this manual cover complete disassembly and reassembly of the unit. 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 6: Maintenance

    INSTALLATION FILLING CASE It is essential to make certain that the case (pump housing) is as full of fluid as possible and remains full during operation and at rest. Always fill to the highest available point. Remove a plug or screw and allow the oil to escape through this point.

  • Page 7: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING Component problems and circuit problems are often inter-related. An improper circuit may operate with apparent success but will cause failure of a particular component with- in 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...
  • Page 8 TROUBLESHOOTING TROUBLESHOOTING effect of trouble possible cause fault which needs remedy (continued) high wear in Improper fluid fluid too thin or thick for operating temperature range pump and motor breakdown of fluid with time/temperature/shearing (continued) effects incorrect additives in new fluid destruction of additive effectiveness with chemical aging improper repair...

  • Page 9: Assembly Tool Drawings

    ASSEMBLY TOOL DRAWINGS MATERIAL CRS 1" DIA. X 2 5/8" (25.4mm) (66.68 mm) Note: Dimensions in ( ) are mm.
  • Page 10 ASSEMBLY TOOL DRAWINGS Material: OHTS 5 5/8 x 1 1/4 DIA (130.17) x (31.75) Hardened Tip RC 58-62 Note: Dimensions in ( ) are mm.

  • Page 11: Disassembly

    UNIT DISASSEMBLY INTRODUCTION The instructions contained in this section cover a complete teardown of the subject pump. Disassemble only as far as necessary to replace or repair any worn parts. DISASSEMBLY Position pump unit so that valve block assembly is on top. A bench or similar suitable sur- face capable of supporting unit should be used.
  • Page 12 UNIT DISASSEMBLY PORT BLOCK See figure 8. Remove four screws (1) that secure the port block (2) to the housing (6). Use caution when removing screws on valve block side to prevent marring valve block face. Remove port block (2) and gasket (5). Remove port plate (4) and port plate pins (3). Note: port plate will in some instances adhere to port block upon disassembly.

  • Page 13: Rework Of Wear Parts

    UNIT DISASSEMBLY REWORK LIMITS OF WEAR max. rework PARTS 6, 7.25 and 8.0 in from original min. dimension after rework port plate face .010” (0,254 mm) .295” (7,49 mm) shoe retainer face .005” (0,127 mm) .307” (7,8 mm) piston shoe face .006”...

  • Page 14: Drive Shaft And Bearing

    S13-43657 barrel & sleeve ass’y.(P7) S13-47511 Figure 2 barrel & sleeve ass’y (P8) S23-12718 auxiliary drive shaft 033-91050 stop 033-53944 barrel holddown spring 033-70493 spring retainer 033-53945 retaining ring 033-70494 Consult DENISON HYDRAULICS Service for parts prior to 1983 units.
  • Page 15 ASSEMBLY PROCEDURES PARTS LIST FOR FIGURE 3 rocker cam, pistons and retainer item description part no qty. retaining ring (yellow) .083" (2.11 mm) 033-70484 retaining ring (green) .081" (2.06 mm) 033-70488 retaining ring (red) .079" (2.01 mm) 033-70490 retaining ring (white) .087" (2.21 mm) 033-72175 retaining ring (blue) .085"...

  • Page 16: Rocker Cam

    ASSEMBLY PROCEDURES ROCKER CAM/PISTONS AND RETAINER Marks Designate Top of Assembly Figure 3 Note: Install items 6, 7, 8, and 9 on side shown of rocker cam if pump model number has “B” suffix. Install on opposite side if “A” suffix. ROCKER CAM See figure 3.

  • Page 17: Pistons And Shoes

    ASSEMBLY PROCEDURES Install tubes (25) in reamed holes in each cover. These tubes must be a tight fit. If tubes ROCKER CAM are loose, the ends can be expanded with a tapered punch. (continued) Tap the tubes in place with a plastic mallet. Install two orifice screws (8) in the servo stem (7).

  • Page 18: Housing

    ASSEMBLY PROCEDURES HOUSING See figure 5. Position housing (1) on a clean flat surface with the large open end up. S13-42335 Wash and dry all parts. During assembly, lapped and ground surfaces should be kept lubricated with clear oil and protected from nicks or surface damage. Clean housing, item #1, and barrel bearing, item #2.

  • Page 19: Port Block

    ASSEMBLY PROCEDURES PORT BLOCK See figure 7. Position the port block (1) on a clean flat surface with the two open ports up. THE OPPOSITE FACE MUST NOT BE SCRATCHED OR DAMAGED. Position needle bearing (2) on tool (Figure T-5) with the marked end of the bearing against the shoulder on the tool and press the bearing (2) into the port block.

  • Page 20: Gerotor And Barrel Holddown

    ASSEMBLY PROCEDURES MOUNTING PORT BLOCK TO HOUSING (continued) Rear View – Width of Arcuate Ports 6 in. is 13/32" (10,3 mm) 7.25 and 8.0 in. is 1/2 (12,7 mm) Figure 8 16 13 GEROTOR IN POSITION FOR RH ROTATION Figure 9 See figure 9.
  • Page 21 ASSEMBLY PROCEDURES PARTS LIST FOR FIGURE 9 item description part no. qty. side plate 033-71492 square key 1/8 x 9/16 211-22034 gerotor and eccentric ring assy. S13-43334 eccentric ring 033-72256 inner and outer gerotor 033-71500 dowel pin 3/16 x 1-9/16 324-21225 gerotor sideplate and bearing assy See below...
  • Page 22 ASSEMBLY PROCEDURES Lubricate O-rings 37. Install (37) in the block (11). VALVE BLOCK before 7-93 (continued) Position the cover (21) over the springs and poppets and install the four screws (39). BE CERTAIN THAT THE SPRINGS ARE IN THE RIGHT POSITION BEFORE TIGHTENING THE SCREWS.

  • Page 23: Valve Block (Before 7-93)

    ASSEMBLY PROCEDURES Valve Block (Before 7-93) S23-00904 Figure 10 See figure 11. VALVE BLOCK (after 7-93) Note: Do not use impact tools or over tighten threaded parts. Wash and dry all parts. During assembly, lapped and ground surfaces should be kept lubricated with clean oil and protected from nicks or surface damage.
  • Page 24 ASSEMBLY PROCEDURES Place springs (33), 1.43" (36.3 mm) into outer most bores at each end of the valve block. VALVE BLOCK Place sequence poppets (30) over these springs. Position seats (27) small shoulder side after 7-93 (continued) first over poppets. Place springs (35), 1.09"...
  • Page 25 ASSEMBLY PROCEDURES Valve Block (After 7-93) S23-12770 Seal Kit S23-00135 Figure 11...
  • Page 26 ASSEMBLY PROCEDURES PARTS LIST FOR FIGURE 11 item description part no. qty. valve block 033-91221 check valve S13-40266 orifice plug (.0465 dia.) (1.18 mm) 033-91249 gasket, O-ring 691-00903 seat 033-70508 screw, socket head 5/16-24 x 1 312-13160 nut, hex jam 5/16-24 335-13100 housing guide 033-70545...

  • Page 27: Valve Block For Special Mounting Of Servo Valve (Before 7-93)

    ASSEMBLY PROCEDURES VALVE BLOCK for special mounting of servo valve (before 7-93) S23-11433 Figure 12 See figure 12. Note: Prior to assembly of reconditioned parts, check finish of gasket surface on valve block and retainer. Must have 60 rms finish with no grinding marks which might carry oil to outside surface.
  • Page 28 ASSEMBLY PROCEDURES Position valve block gasket (29) on valve block. Take care that none of the gasket is cov- VALVE BLOCK ering the valve seats. for special mounting of servo valve before 7-93 (continued) a. Position retainer plate (42) with O-ring grooves facing up, over valve block gasket. Install four button-head cap screws (43), torque to 30 in.-lbs.
  • Page 29 ASSEMBLY PROCEDURES PARTS LIST FOR FIGURE 12 (before 7-93) item description part no. qty. valve cover 033-54391 valve check S13-40266 orifice #56 (.0465) 1/16 pt 033-25528 O-ring, 90 S-1 ARP 903 691-00903 seat 033-70508 set screw, 5/16-24 x 1 cup pt 312-13160 hex jam nut 335-13100...

  • Page 30: Valve Block For Special Mounting Of Servo Valve (After 7-93)

    ASSEMBLY PROCEDURES VALVE BLOCK for special mounting of servo valve (after 7-93) S23-12776 Figure 13 See figure 13. Note: Do not use impact tools or over tighten threaded parts. Wash and dry all parts. During assembly, lapped and ground surfaces should be kept lubricated with clean oil and protected from nicks or surface damage.
  • Page 31 ASSEMBLY PROCEDURES Place springs (35), 1.09" (27.7 mm) into bores next to the sequence poppet valves of VALVE BLOCK step 5. Place dual relief poppet (31) over these springs. Position seats (28) with the for special mounting of servo valve groove side facing up, over poppets.
  • Page 32 ASSEMBLY PROCEDURES PARTS LIST FOR FIGURE 13 (after 7-93) item description part no. qty. valve block 033-91335 valve check S13-40266 orifice #56 (.0465) 033-91249 O-ring, 90 S-1 ARP 903 691-00903 seat 033-70508 set screw, 5/16-24 x 1 cup pt. 312-13160 hex jam nut 335-13100 guide-housing...

  • Page 33: Output Controls

    ASSEMBLY PROCEDURES PARTS LIST FOR FIGURE 14 item description part no. qty. no. 3 splined shaft assy. (see fig. 1) S13-41805 no. 2 keyed shaft assy. (see fig. 1) S15-41806 shim .008 (.203 mm) (use only 1) 033-53948 shim .007 (.178 mm) 033-53949 ret.

  • Page 34: Shaft And Seal Installation

    ASSEMBLY PROCEDURES Valve Block See Fig. 10, 11, 12, 13 Figure 14 SHAFT AND SEAL INSTALLATION See figure 14. Stand the pump in an upright position with the port block inlet and outlet pads turned down. Install the shaft and bearing (1) assembly in the mounting flange and cradle. Be certain that there are no burrs or sharp edges on shaft seal area of the shaft.

  • Page 35: Counter-Balance Servo Stem

    ASSEMBLY PROCEDURES See figure 14. The seal assembly (4) is available as a complete unit only. Caution: Before installing the seal assembly examine all the parts. The lapped seal seat and the carbon ring have a precision finish that must be handled with care. Be certain that both parts are free of scratches, marks and cracks.
  • Page 36 ASSEMBLY PROCEDURES PARTS LIST FOR FIGURE 15 item description part no. qty. adapter — SAE-A with shuttle pad 033-91015 adapter — SAE-B with shuttle pad 033-57967 adapter — SAE-A no shuttle 033-57958 adapter — SAE B no shuttle 033-57957 coupling 033-57963 insert —...

  • Page 37: Pilot Valve

    ASSEMBLY PROCEDURES Exploded View of Shuttle Valve Exploded View of Pilot Valve Figure 16 PILOT VALVE See figure 16. Insert seat (2-8) into cap (2-3) and seat in bottom of bore. Install small end first of block (2-7) into bore and against seat. Install small end first of piston (2-6) into block (2-7).

  • Page 38: Shuttle Valve Mounting

    ASSEMBLY PROCEDURES Insert piston (6) into sleeve (5) and place spring (7) into piston (6). SHUTTLE VALVE (continued) Lube O-ring (10) and place onto the sleeve (5). Lube O-rings which come on pilot valve sub-assembly (2). Mount pilot valve cap sub-assembly (2) onto shuttle block (1). Use three S.H.C. screws (14) and the one screw which comes with the pilot valve sub-assembly.

  • Page 39: Important Instructions

    IMPORTANT INSTRUCTIONS Without Filter No Plug External Filter With Plug CAUTION: The isolation plug enclosed is to be used ONLY if an external filter circuit INSTRUCTIONS FOR is provided. DO NOT operate this unit with the isolation plug installed unless an exter- REPLENISHING CIRCUIT nal line has been provided.

  • Page 40: Hydraulic Circuit

    HYDRAULIC CIRCUIT Revised...
  • Page 41 HYDRAULIC CIRCUIT Revised...

  • Page 42: Test Procedure

    TEST PROCEDURES GENERAL REQUIREMENTS 1. Maximum runout between pump shaft and electric motor shaft .003 (.076 mm) T.I.R. A floating shaft must have a support in mounting bracket. A fixed shaft should not have a support bearing in mounting bracket. 2.
  • Page 43 TEST PROCEDURES If pressures are incorrect, remove replenishing relief valve pilot and increase or decrease BASIC PUMP TEST pressure as required. (One full turn on adj. screw will cause pressure to change approx- (continued) imately 50 PSI) (3.4 bar). Re-torque locknut to 20-25 in-lbs. (2.3-2.8 Nm). Note: There is no servo relief valve adjustment.

  • Page 44: Ordering Code

    ORDERING CODE Revised...
  • Page 45 ORDERING CODE...
  • Page 46 AVAILABLE GOLD CUP PUMP CONTROL COMBINATIONS 2M2 *00 2N2 *00 5A2 *00 7D6 *00 8A2 *00 8C2 *00 9A2 *00 2M2 *01 2N2 *01 5A2 *01 7D6 *01 8A2 *01 8C2 *01 9A2 *01 2M2 *02 2N2 *02 8A2 *02 8C2 *02 2M2 *03 2N2 *03...
  • Page 47 NOTES...
  • Page 48 : / / w w w . d e n i s o n h y d r a u l i c s . c o m © Copyright 2002 Denison Hydraulics Inc. All rights reserved. 4-30-02...

This manual is also suitable for:

Goldcup p6Goldcup p7Goldcup p8s

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