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Axial Piston Pump Gold Cup Series P24P/S E-mod., P30P

1. H2 SAE 6 STR THD ALT SERVO INLET a PLACES OFF 2 PLACES L 17 34 5 53 VA REF AIR BLEED PORT FOR FILLING CASE 440 3 140 3 19 80 84 V SAE 4 STR THD COMPENSATOR VENT REF Hoe ON VERTICAL MTD UNITS OPTIONAL KEYED SHAFT D1 SAE 20 STR THD gt 502 8 237 21 3 SAE 4 STR THD CASE DRAIN es SOEN m K SAE 32 STR THD 60 2 e 2500 OPTIONAL REPLEN PUMP SUPPLY INLET Se 498 225 1270 571 12 65 BG2 SAE 8 STR THD IDN 614 SYSTEM GAGE 1 999 1 998 ou T 163 6 50 77 50 75 8t 4 17 5 59 105 9 TS 1 66 1 75 9 1 53 A 1 42 2 pa 88 91 2322 tt 3 06 0 1 75 77 7 2 218 4 20 44 4 2 212 92 25 106 7 56 34 M aan 6 4 2836 O 23 4 6 44 163 6 2 x45 t 60 AG2 SAE 8 STR THD m SYSTEM A GAGE H 18 178 45 2 KG SAE 6 STR THD REPLENISHING GAUGE 3000 PSI aa 6853 REF Le 262 SC
2. 8 14 206 7 e 19 192 TRIMMER ADJUSTMENT MAX FIGURE 2 A CONTROL MTG POSITION CONTROL PUMP FIND PUMP ROTARY SERVO INPUT PORT PORT ale FR Ber OPTION PACKAGE FIGURE ROT SHAFT ROTATION EY 2 cw cw INLET OUTLET 1 24 2 CCW CCW INLET OUTLET 4A2 amp a ov P30P 2 CCW OUTLET INLET o eb Sl 2 ccw cw OUTLET INLET Ve 5 ES 1 4 20 UNC TAP x 25 DEEP VIEW B B VOLUME STOP LOCKNUT 6 4 MAX VOLUME STOP T p EE 7 i dod Pei _ 513 i 508 MAJOR DIA KNURL i 5 189 32 TEETH PER INCH gt SEE MANUAL 12 50 I 1 O OVERRIDE DETAIL EA EN H MANUAL OVERRIDE SHAFT DETAIL 1 SCALE FULL i O i i 1 Li NOTES qe ES Fl G U R E 1 1 FOR DIMENSIONS amp PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION 4 P24P BASIC INSTALLATION LESS CONTROLS _23 9922 D D 5 BASIC INSTALLATION LESS CONTROLS _23 9913 D 2 REFERENCE TO PUMP ROTATION R CW 8 L CCW IS AS VIEWED FROM SHAFT END AD 3 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS MALES i Og n Lil J ah B CONTROL MTG POSITION 2 Y MAX MAX 7 CONTROL PUMP FIND PUMP ROTARY SERVO INPUT PORT PORT
3. MAX VOL STOP SCALE 4X A 8 14 TRIMMER ADJ 206 8 8 64 2 9 27 55 MAX VOL STOP 219 5 235 4 14 0 I qu ER 9 gn 8 19 i 9 66 245 3 PL SOLENOID VALVE B SOLENOID VALVE A A DV EXTERNAL DRAI 43 D3 amp KA REF PILOT STAGE VALVE o 277 SAE 4 STR THD D3 DRAIN CONN SAE 16 STR THD B CONTROL MTG POSITION CONTROL PUMP PUMP MANUAL OVERRIDE PORT PORT TORQUE LIMITER KA ONTO piace PUMP ENERGIZE SOLENOID ee Llei oF d Cen E cw cow INLET OUTLET F i P24S 9A4 OR P30S cw B cw OUTLET INLET E 61 www comoso com 8 14 206 7 VIEW A A F TORQUE ADJ SEE CHART 18 05 17 05 458 5 305 4332 245 gt 7 3 P308 8895 245 gt O C INTERNAL AUX PUMP SERVO A SUPPLY C OPTIONAL INTERNAL AUX PUMP INLET SAE 32 STR THD SERVO amp REPLEN SUPPLY INLET SAE 16 STR THD P24S OR P30S WITH 9A4 CONTROL W INTERNAL CARTRIDGE LESS REAR DRIVE CW B MTG SAE F 4 BOLT MTG 23 9935 ORDERING CODE Supra ZHO9 OVAOTI ien I0dr 70 uues IH ZHOS OVAOFC 10 CATT ATA 00 IO0 osuuoo
4. 46 SEE MANUAL OVERRIDE DETAIL X VOLUME ADJ SEE CHART Y VOLUME ADJ SEE CHART www comoso com REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS FIGURE 1 CONTROL PUMP FIND PUMP ROTARY SERVO INPUT PORT PORT OPTION PACKAGE FIGURE ROT sPRG OFF SETTO FULL A B EVOL ADJ Y VOL ADJ PaP 1 cw CW ROT FULL TO MIN INLET OUTLET MIN VOLUME STOP MAX VOLUME STOP 102 P30P 1 CCW CCW ROT FULL TO MIN INLET OUTLET MAX VOLUME STOP MIN VOLUME STOP Y MAX xdi __ 7 2 e N o S LA ECH P24P OR P30P WITH 102 CONTROL WITH INTERNAL CARTRIDGE CW CCW ROTATION SAE F 4 BOLT MTG 23 9933 NOTES INSTALLATION DRAWING 1 FOR DIMENSIONS amp PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS _23 9922 D P30P BASIC INSTALLATION LESS CONTROLS _23 9913 D 2 REFERENCE TO PUMP ROTATION R CW 8 L CCW IS AS VIEWED FROM SHAFT END 3 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 1 4 20 UNC x 25_ DEEP 6 4
5. 19 Pp 19 MAX MAX Es 1 2 13 UNC 2B X 88 DEEP 4 PLACES 22 4 e eve Yo Le 138 34 9 2 75 M e VIEW A A L 2 52 641 18 05 17 05 458 5 09 433 2 249 20 68 paps 19 68 s 525 3 499 9 1 50 3000 PSI SAA T209 BAR 1 4 4 BOLT FLG CONN PORTING NOTE PORT POSITIONS ARE 28 58 27 58 AVAILABLE IN ANY ONE OF FOUR POSITIONS 7259 700 6 FOR FURTHER INFORMATION CONSULT S O 30 19 29 19 AND OR T6C SALES BULLETIN 766 8 7415 PAS gt POSITION 03 SHOWN MAX VOL STOP 1 00 TRIMMER ADJ LOCK TRIMMER ADJ 25 4 MAX VOL STOP 9 62 E i E 1 9 66 10 01 2453 2543 P1 CONTROL PORT SAE 4 STR THD P2 CONTROL PORT SAE 4 STR THD B CONTROL MTG POSITION CONTROL PUMP PUMP CONTROL PRESSURE TO MANUAL OVERRIDE PORT PORT OPTION PACKAGE ROT SAE 4 STR THD CONTROL PORT SH
6. www comoso com 41 CIRCUITS Figure 15 P24 30S www comoso com 42 INSTALLATION DRAWING 43 www comoso com H2 SAE 6 STR THD ALT SERVO INLET SAO AER 18 agies 18 pre 2 PLACES 1534 T VARRER APLACES 669 AIR BLEED PORT FOR FILLING CASE B 414 9 140 3 18 80 84 V SAE 4 STR THD COMPENSATOR VENT REF si pe ON VERTICAL OPTIONAL KEYED SHAFT D1 SAE 20 STR THD SM 477 4 2 37 21 3 E 4 STR THD CASE DRAIN 2 83 _ A K SAE 32 STR THD 60 2 Se 71 9 OPTIONAL REPLEN PUMP SUPPLY INLET e 1 68 y 488 225 LG 1270 57 1 1 12 65
7. O P1 CONTROL PORT A SAE 4 STR THD P2 CONTROL PORT SAE 4 STR THD B CONTROL MTG POSITION CONTROL PUMP PUMP CONTROL PRESSURE TO MANUAL OVERRIDE PORT PORT OPTION PACKAGE ROT SAE 4STR THD CONTROL PORT SHAFT ROTATION At B P24P OR P30P WITH 8A2 CONTROL cw COW INLET OUTLET WITH INTERNAL CARTRIDGE iu cow 2 ew INLET OUTLET CW CCW ROTATION SAE F 4 BOLT MTG P30P cw par cw OUTLET INLET ccw OUTLET INLET 23 9915 2 of 2 57 WWW comoso com NOTES INSTALLATION DRAWING FOR DIMENSIONS 8 PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS _23 9913 D VIEWED FROM SHAFT END 1 4 20 UNC x 25 DEEP 6 4 45 4 513 REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 508 MAJOR DIA KNURL 1808 32 TEETH PER INCH 12 90 MANUAL OVERRIDE SHAFT DETAIL TO OPERATE DISCONNECT OIL SUPPLY TO CONTROL PORTS SCALE NONE c 8 15 4 207 1 e rz Sl E 208 O O Y rx DV EXTERNAL DRAIN PILOT STAGE VALVE SAE 4 STR THD 43 D3 8 REF 110 7 ES
8. avs OUTO pre Apuo pzd 101 Louny ATUO 9 2 1 Og 103 pasop 2 uedo STP Apuo p T2 TT 8 04401 uedo STD gnano pes o o S3esoed opns 22 ysn jueureoer STD pesoro xttp rut enbzoj YA STP a3eyoed opns 29 nbio tnra STD SATIP NIY tit Tata STD pesopo qu ur op STD oI pesopo eAnp nui sabio 491 3ueursoedsri A91 09 106 e1 urno 0706 21 00 EOP exrurno Ju ur se dsiq pjop www comoso com 62 ORDERING CODE 935 sdumd JISOOSTA MOT 107 SULIB9Q pouneg paseo zuoiq a durexa Teroads dN d ON SuoN I uonuv ripourcr ds pegtoeds Ajere das snw ZW eroeds s mnb r pejunour 4 st OU 0 oN Sununou ceu1 XT uo W T 30 rcdXv LZT AVS T HVS ATWO 4 1 06 2 1 114 091 AVS T HVS ATWO 4
9. 45 11 4 4 I Y CONTROL PORT VIEW A A 1 SAE 4 STR THD 2 X CONTROL PORT 513 SAE 4 STR THD 508 MAJOR DIA KNURL 13 03 82 TEETH PER INCH MANUAL OVERRIDE SHAFT DETAIL TO OPERATE DISCONNECT OIL VOL STOP MAX VOL STOP SUPPLY TO CONTROL PORTS SCALE NONE 1 A 844 F 206 8 854 25 4 1 00 a 54 11 A mi E 2 2 47 ss ee T EF ej x 1 4 1 TRIMMER ADJ A B CONTROL MTG POSITION CONTROL PUMP PUMP CONTROL PRESSURE TO MANUAL OVERRIDE PORT PORT OPTION PACKAGE ROT CONTROL SHAFT ROTATION P24P OR P30P WITH 2H2 CONTROL x INLET SUITES WITH INTERNAL CARTRIDGE icu cow Y ew INLET OUTLET CW CCW ROTATION SAE F 4 BOLT MTG P30P cw cw OUTLET INLET ccw x CCW OUTLET INLET 23 9926 2 of 2 50 www comoso com INSTALLATION DRAWING
10. ZHO9 IVAOT I tr fot e lalek epoo durexq jeeus 1equunu S o u02 NC 29 xINZ juauraJe dsrp pue 0 100 Opts 10 uo TOYUOS AT apis y pod uo ojuoo mun 0 007 OC 9eqpsa uonrsod 4 uontsod 29 anbio lojeorpur ATuo spun Ju ur p dsrp 107 suo S O YUO ese1q 5405 SUMJOA epqejsnipe 0116 ornerpA onoerq 84018 umoa DG e A TOONS O1J99TH oyeg 5405 eumpoA epqejsnfpe 54015 sum oa Au Toto e 04198 Amon VV 9 AeA OI UST 29 Aea OI 1 2 SATPACATOS 01 UNA OI UST 2 01 TIM OT Yor oneurojne 29 54018 Sumo Umumxeur DG e M TOONS O1J99TH 54015 SUMJOA q sn pe m rayons Tonuoo or eurojne 54
11. 45 114 Z gt E A 7 uw 513 27 508 MAJOR DIA KNURL 13 03 82 TEETH PER INCH 1290 SCALE NONE MANUAL OVERRIDE SHAFT DETAIL TO OPERATE DISCONNECT OIL SUPPLY TO CONTROL PORTS 2 SE Se aP PPK EE ET 8 14 206 7 A CONTROL MTG POSITION CONTROL PUMP PUMP CONTROL PRESSURE TO MANUAL OVERRIDE PORT PORT OPTION PACKAGE ROT PORT PORT Y SHAFT ROTATION A B P24P SPRING amp OFFSET P30P cw MIN VOLUME MAX VOLUME cw INLET OUTLET TO ZERO CCW MAX VOLUME MIN VOLUME CCW INLET OUTLET 47 www comoso com 8 14 206 8 Y CONTROL PORT 1 00 1 8 27 DRYSEAL N P T F X CONTROL PORT 1 8 27 DRYSEAL N P T F 2 50 63 5 MIN VOLUME STOP CW PUMP ROTATION MIN VOLUME STOP CCW PUMP ROTATION MAX VOLUME STOP CCW PUMP ROTATION MAX VOLUME STOP CW PUMP ROTATION VIEW A A P24P OR P30P WITH 242 CONTROL WITH INTERNAL CARTRIDGE CW CCW ROTATION SAE F 4 BOLT MTG 23 9934 10f2 INS
12. 523 11514 523 17039 523 18017 523 18018 523 18022 523 18023 523 17040 823 18019 823 17041 0 523 15089 523 17042 N w go r E amp B N m go r 523 18020 523 16332 523 18021 523 16333 N Seal Kits for P24 30 Gold Cup Pumps with T6C Auxiliary Pumps SHAFT ROT COMPLETE SHUTTLE SHAFT SEAL KIT TYPE SEAL KIT REL 823 11600 823 11516 523 15089 823 15696 823 16332 823 15697 523 16333 EE w N Notes 44 0 FOR BUNA 4 for EPR Rubber 5 for VITON place of 4 www comoso com INTRODUCTION DESCRIPTION MOUNTING REAR PUMP MOUNTING SHAFT INFORMATION PIPING INSTALLATION The DENISON HYDRAULICS Goldcup 24 and 30 axial piston pumps feature advance design concepts which are time proven and provide for advanced pumping and control concepts The instructions contained in this manual cover complete disassembly and re assembly of the unit Before proceeding with the disassembly or reassembly of any unit this manual should be studied in ordered to become familiar with proper order and parts nomenclature The use of a rocker cam to control the pump displacement pro vides a small package size reduces wear and speeds control response The control vane actuator eliminates linkage and backlash inherent in typical stroking cylinder designs
13. 03372379 3 32 replen spring 039322411 1 33 sequence amp servospring os37ost2 3 34 servoreliefpoppet 03354398 1 35 dual relief spring 1033 71086 2 36 piotreplen S2312699 1 37 1 0 0 61000 1 38 spol 053 5452 1 39 orig 691 00008 1 41 soc hd screw 10 24 x 1 1 4 lg 1358 10180 4 42 retainerplate 03391422 1 43 screw aoe 4 44 servoreliefseat 033 54399 1 45 acornnut5 16 24 1327 25006 1 46 rollpint 8xS lg 325 08120 2 47 1 671 0013 2 48 oring 67100041 2 50 plug7 16 20 44900013 1 53 soc hd screw 3 8 16 x4 lg 3858 16360 4 54 pug 2 03840132 4 55 servovalve use w F or 7G controls 356 31043 2 56 o ring servovalve use w 7F or 7G controls 691 00011 2 57 pin servovalve use w 7F or 7G S23 02208 1 58 Le soten 306400132 4 61 orifice 456 0 0465 1 18mm _____ 03325528 1 35 www comoso com ASSEMBLY PROCEDURE VALVE BLOCK ASSEMBLY FOR SERVO VALVE MOUNTING Figure 13 continued 19120 79 89 closed loop w servovalve adapter amp on off compensator control Assembly No S23 12776 P24P P30P 8 P24S P30S Assembly No S23 12798 P24P P30P amp P2
14. 06 2 11 114 241 AVS C HVS OATAIOE VO F L TTd 1077 21 AVS Y C LCT 7 9 606 24 Y W T 88 L 0d 101 0121 AVS D HVS 10 6 10 T AVS 9 27 101 S VSXX SOE VC V VTTd IN 1 4 X 88 L 9d 10 7 101 AVS g 3VS Y SUON x EU I9 X 4 1 4 d UO prepuejs dumd oN 9 ATWO X S 40 7d 831 99 07001 AST urno Qro ATWO X S d0 rZd 401 09 898 gt ATWO X S d0 rzd 401 09 6 ACT urno pg E ATWO X S d0 rzd 401 09 680 Aat urno oc f pormbaz Surqsruejde1 KUO X S d0 pzd CAS1 99 Z L D Aa UTM en T mop Sunjstusyder ATUO X 8 40 P7d CA91 99 poc Ae1irurno 107 parmbaz st ou Jt 1110 0 prepueis X S d0 rzd 491 99 op 1877 peuray A91 99 Ae urno Z 2 eeiDep 7 uu poc urno 0 22 UMA se1dop 6T prepurig Wad Y 4 4 40 suopdo poonpow 810 1102 6 A IA 0 req 82 0D 184 oor 0 20 184 oz L Sd 08 00 0 req oe c rsd cep SL 00 req pz 6 sd oce CL 8104 109 8 TO eene 15 Y
15. E OPTION PACKAGE FIGURE ROT SHAFT ROTATION B 1 cw CCW INLET OUTLET 2 ccw OUTLET 4A2 A 1 cw INLET 1 cw cw OUTLET INLET i SEE MANUAL OVERRIDE DETAIL 1 ccw cew OUTLET INLET S i P24P OR P30P WITH 4A2 CONTROL WITH INTERNAL CARTRIDGE bh VOLUME STOP LOCKNUT CW CCW ROTATION SAE F 4 BOLT MTG A MAX VOLUME STOP L TRIMMER ADJUSTMENT 51 www comoso com 23 9927 TRIMMER ADJUSTMENT MAX E o O 1 1 MAX VOLUME STOP B Lee Ls B 19 INSTALLATION DRAWING VIEW B B NULL ADJUSTING SCREW Fl RE 2 CONTROL MTG POSITION G U CONTROL PUMP FIND PUMP ROTARY SERVO INPUT PORT PORT OPTION PACKAGE FIGURE ROT SHAFT ROTATION A p 2 Cw CW INLET OUTLET P24P OUTLET 5A2 2 CCW INLET P30P 2 Cw CCW OUTLET INLET 2 CCW cw OUTLET INLET TE INT 14 2 49__ i 12 5 3760 13755 22 9 550 DA AS 5 9 538 41 s i Em 75 DIA WITH 20 WIDE FLAT S SERVO INLET SAE 4 STR THD 7 15 a SEE MANUAL 277 OVERRIDE DETAIL MANUAL OVE
16. joys enueur 00 Domus penueur OTI 5101 009 de AA y E 00 pueqpeep Ota 51013002 y yS PALO Teas PIM ZHOS 2VAOTI SAPA 1048 90 1ojo uuoo UNA DAAH APA TOCIE 0 eaea OU 95 N E0CD 640392 0 Suum APA 1007 T WAT SITTITA ATT Seat TATI www comoso com 63 AVAILABLE CONTROL COMBINATIONS GOLD CUP PUMP CONTROL COMBINATIONS 2M2 00 2N2 00 5A2 00 7D6 00 8A2 00 8C2 00 2 00 2M2 01 2 2 01 5A2 01 7D6 01 8A2 01 8C2 01 9A2 01 2 2 402 2N2 02 8A2 02 8 2 02 2M2 03 2 2 03 5A4 00 7D7 00 8A2 03 8C2 03 9 4 00 2M2 04 2 2 04 5A4 01 7D7 01 8A2 04 9A4 01 2M2 05 2 2 05 8C4 00 2M2 06 2 2 06 DAG 00 708 00 8A4 00 8C4 01 9A6 00 2 2 07 2N2 07 5A6 01 7D8 01 8A4 01 8C4 02 9 6 01 02 8C4 03 2M4 00 2N4 00 5A7 00 7F6 01 8A4 03 9A7 00 2M4 01 2N4 01 5A7 01 01 04 8C6 00 9 7 01 2M4 02 2N4 02 7F8 01 8 6 01 2M4 03 2N4 03 5A8 00 DAD 00 8C6 02 9A8 00 2M4 04 2N4 04 5A8 01 7J6 00 8A6 01 8C6 03 9A8 01 2M4 05 2 4 05 7J6 01 8A6 02 2 4 06 2N4 06 5C2 00 DAD 03 8C7 00 9C2 00 2 4 07 2N4 07 5C2 01 147 00 DAD 04 8 7 01 9C2 01 737 01 8C7 02 2M6 00 2N6 00 5 4 00 00 8C7 03 9 4 00 2M6 01 2N6 01 5C4 01 7J8 00 8A7 01 9C4 0
17. MANUAL OVERRIDE DETAIL Va SEE MANUAL TO OPERATE DISCONNECT OIL OVERRIDE DETAIL SUPPLY TO SERVO S INLET PORT 50in lbs DO NOT EXCEED TORQUE ELEC HYD STROKER ELECTRICAL INPUT INPUT 19 CCW Iccw MECHSTOP CN CURRENT AT FULL DISPL A A 350 MA NOM POLARITY COIL RESISTANCE ELECTRICAL CONN 250 NOM SEE NOTE 4 WITH ELECTRICAL POLARITY AS SHOWN cw EEN B NULL ADJUSTING SCREW INPUT SHAFT WILL ROTATE CCW NOTES 1 FOR DIMENSIONS amp PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS 23 9913 D F G U R E 1 2 REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS VIEWED FROM SHAFT END 3 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 4 ELECT RECEPTACLE CONN 5 8 24 x 390 MATING CONNECTOR HALF 53106 1061 45 97 O VIEW A A 221 7 d Z BRAKE ACTUATOR 11 43 SAE 6 STR THD 290 3 al ELECTRICAL CONN 11 24 8 51 814 _ SEE NOTE 4 H 4 een pm ER B CONTROL MTG POSITION TRIMMER ADJUSTMENT Y MAX MAX 7 CONTROL PUMP FIND P
18. U p SERVOVALVE WIRING SCHEMATIC DENISON 099 13142 MATING CONN DENISON 721 30059 REF RED 15VDC 15VDC BLUE EN OUT clic OUT GREEN COMMON 15VDC V BLACK DD 15VDC RVDT WIRING SCHEMATIC DENISON 788 20002 2 4VDC OUT AT 19 CAM ANGLE 11 29 286 8 H1 15 12 UNF 37 FLARED TYPE SAE ELBOW AUX PUMP SERVO amp REPLEN INLET FROM EXTERNAL FILTER 216 9 q Y d Y q Q B CONTROL MTG POSITION CONTROL PUMP PUMP VOLUME INDICATOR PORT PORT OPTION PACKAGE ROT SHAFT ROTATION cw cew INLET OUTLET P24P ccw cw INLET OUTLET 7E2 amp P30P cw cw OUTLET INLET ccw ccw OUTLET INLET 55 NOTES 1 FOR DIMENSIONS amp PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 0 P30P BASIC INSTALLATION LESS CONTROLS _23 9913 D 2 REFERENCE TO PUMP ROTATION R CW 8 L CCW IS AS VIEWED FROM SHAFT END 3 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS www comoso com VIEW A A OPTIONA
19. 1 gt e Ei FIGURE 11 EXPLODED VIEW OF SHUTTLE VALVE EXPLODED VIEW OF PILOT VALVE EXT DRAIN PARTS LIST FOR FIGURE 11 S23 11966 item p part quantity pilot valve external drain 6 piston A 036 292 1 8 sprin w o03357ie8M 2 9 1691 00125 2 plug 121 o ring A A AAN ARTS LIST FOR FIGURE 11 S23 11966 ITEM 2 Spacer 2 10 2 10 2 19 hex soc plug 2 3 4 5 6 7 8 9 www comoso com shuttle valve adapter shuttle valve mounting VALVE BLOCK ASSEMBLY Figure 12 30 ASSEMBLY PROCEDURE See figure 10 Lubricate tetraseals 15 and o ring 16 and place in c bores on shuttle valve adapter s 17 mounting surface Carefully attach shuttle adapter to port block using soc hd cap screws 18 Torque to 75 lbs ft 102 Nm Note Bolt pattern for shuttle adapter is non symmetrical and can be mounted only one Way See figure 11 Lubricate tetraseals 11 and place in c bores of shuttle v alve s mount ing surface Carefully attach shuttle valve to shuttle valve adapter using screws 13 Torque to 75 Ibs ft 102 Nm Note Bolt pattern for shuttle adapter is non symmetrical and can be mounted only one way 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 surf
20. Barrel assembly can be removed by lifting with auxiliary shaft The pistons will remain with the cam assembly These parts are precision finished and must be handled with extreme care See figure 8 Remove the check valve assemblies 7 from the port block Remove plugs 9 and 10 Remove two screws 4 lockwashers 5 check rings 6 and clamps 3 See figure 7 NOTE Pump cam must be on center 0 angle before removing shaft Remove four screws 5 seal retainer 2 gaskets 4 and stationary part of shaft seal assembly 3 Refer to view of item 3 Remove the carbon ring and the remainder of the shaft seal from the shaft Remove shaft and bearing assembly 1 See figure 3 Remove pressure feed tubes 4 from the cradle DO NOT BEND THESE LINES Discard all bent lines Remove the rocker cam assembly from the mounting flange by carefully tilting mount ing flange on its side and using a 1 4 20 threaded rod as a puller remove plugs 11 with o rings 8 and then remove screws 9 attaching cradle to mounting flange Position rocker cam assembly on a clean surface with the override tubes 2 ina horizontal position and located at the top See figure 2 Mark the cam 21 and cradle 18 as indicated These marks will determine positioning of parts during assembly Position the assembly in an upright position on the flat surface of the cradle Remove the retaining ring 1 thrust washer 2 piston and shoe assembly 4
21. 12 7mm x 76 2mm 19mm DIA x 2 54mm 4140 Steel HDN GR T4 Shaft seal installation tool rear adapter 15 27 35 001 34 950 1 378 NOTES 1 376 s7 048 1 Remove all burrs amp break sharp 1020 5 edges 010 005 R 254 127 2 241 2 Part to be heat treated to Re 50 55 SMOOTH 3 Material 4140 or equivalent INTERSECTION ig 4 Dimensions in mm 2 3 10 www comoso com INTRODUCTION DISASSEMBLY VALVE BLOCK after 7 93 CONTROL COVERS SERVO REPLENISH PUMP AND BARREL HOLDDOWN 11 UNIT DISASSEMBLY 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 CAUTION On 24 series units relax barrel holddown prior to removal of shaft seal or main shaft Failure to follow this procedure may result in pump failure NOTE The four main assembly bolts 1 Figure 9 are torqued to 450 Ibs ft 610 2 Nm These bolts should be loosened prior to removing unit for disassembly Position pump unit so that the valve block assembly 11 12 Figure 10 is on top A bench or similar suitable surface capable of supporting unit should be used Disassembly area should be clean See figure 10 Remove the eight hex head cap screws 12 and lift the entire block assembly from the port block See figure 13 Remove the four hex head cap screws 58 and four soc hd scre
22. 18 on covers 23 www comoso com CONTROL COVER ASSEMBLY Continuea PORT BLOCK ASSEMBLY FIGURE 8 amp 4o PORT BLOCK INSTALLATION 24 A Qv 0 9 0 A ASSEMBLY PROCEDURE Install the cover assemblies 14 amp 15 over the dowel pins on the housing pads and secure with seal 12 and screws 13 Torque to 30 Ibs ft 40 8 Nm See figure 8 Position the port block 1 on a clean flat surface with two open ports up The finished faces must not be scratched or damaged Compress the ring checks 3 and install in the two system ports and align holes in the rings with the side holes in the port walls Place lockwashers 5 on screws 4 and install screws through port wall and ring checks and thread into nut 3 Torque to 10 Ibs ft 13 56 Nm Install two check valve assemblies 7 in valve face of port block Torque to 30 Ibs ft 40 8 Nm Install nine hex hd soc plugs 9 and o rings 8 into port block Torque to 16 Ibs ft 22 Nm Install hex soc plugs 10 and o ring 11 into port block Torque to 50 Ibs ft 68 Nm Install AVSEAL plugs 2 into port block PARTS LIST FOR FIGURE 8 P24 30P P24 30S description S23 15105 S23 15127 quantity quantity port block 033 91564 port block w shuttle S 033 91604 033 72355 13 3 o ring 3 See figure 9 Position the pump with open end of the housing assemb ly 6 facing up Install new gasket 5 on the housing Do no
23. DENISON HYDRAULICS recom mends lithium molybdenum disulfide or similar grease The female coupling should be hardened to 27 45 Rc and must conform to SAE J498B 1971 class 1 flat root side fit Keyed High strength heat treated keys must be used Replacement keys must be hardened to 27 34 Rc The key corners must be chamfered 0 030 0 040 0 75 1mm at 45 to clear radii that exist in the keyway Note Do not impact coupling to force it onto the shaft A threaded hole size M16 is provided in the end of the shaft Both types of shafts will accept a side load of 1000 Ibs 454 kg at the center of the spline or key with a B10 life of 9880 hours at 1800 r pm or 11856 hours at 1500 rpm Connect inlet and outlet lines to the por t block of the pump The maximum case pressure is 75 psi 5 7 bar contin uous 125 psi 8 6 bar inter mit tent When connecting case drain line make certain that drain plumbing passes above highest point of the pump before passing to the reservoir If not install a 5 psi 0 3 bar case pressure check valve to be certain the case is filled with oil at all times Note High case pressure will result in reduced shaft bear ing B10 life The case leakage line must be of sufficient size to prevent back pressure in excess of 75 psi 5 7 bar and returned to the reservoir below the surface of the oil as far from the supply as possible All fluid lines whether pipe tubing or hose must be adequate size to assure free flow thro
24. EH 275 Dia x 1 E 7 000 69 8 1B 6998 E 177 80 320 4 87 177 75 475 83 7 2 123 7 120 7 gt 7 31 6 10 1 1 1 154 9 185 7 A2 ase AG2 amp BG2 REF 89 138 lt Ei 1 35 0 Ss G SAE 12 STR THD ei AG2 REF B D2 SAE 20 STR THD s AUX PUMP SERVO amp REPLEN SAE INVOLUTE SPLINE DATA J498 B 1969 CASE DRAIN OUTLET TO EXTERNAL FILTER 485 FLAT ROOT SIDE FIT EXTERNAL CLASS 1 183 30 PRESSURE ANGLE 18 80 Ba co 88 E 97 0 15 TEETH 477 4 UE NOTES 22 3 777 28 5 1 9710 1 9660 50 063 49 936 MAJOR DIA e 660 1 1 REFERENCE TO PUMP ROTATION R CW 8 L CCW IS AS 22 89 i VIEWED FROM SHAFT END 7 581 4 1 2 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 1 75 ae DIA aa Y CASE OVERFLOW PORT FOR SUBMERGING gt PLACES NEAR SIDE amp FAR SIDE 1 DETAIL A BEARING ON VERTICAL MTD UNITS SEE DETAIL A SAE 4 STR THD BASIC 24 CIPR E MOD V V PUMP SAE 2 00 6000 PSI WITHOUT CONTROLS S4 10UNCx 15 peep som SAE F 4 BOLT MOUNTING amp PLACES 98 1 23 9922 INSTALLATION DRAWING 1 06
25. figure 13 valve block for servo valve test procedure alternate test procedure control test refer to control service manual 51 030 hydraulic circuit P24 30P hydraulic circuit P24 30S installation drawings ordering code conversions amp formulas WWW comoso com PAGE 0000000010101 010101 HW OO OO OONN N N N STD ch ch ch zb ch N O N O O O O O 1 gt GQ GQ QO N 00000 I OO Oo Om Om QO O 43 61 62 65 TECHNICAL CHARACTERISTICS TECHNICAL CHARACTERISTICS specification term Goldcup 24 Goldcup 30 edisplacement at max angle in rev 24 6 30 6 cm rev 403 501 4 pressure continuous psi 5000 5000 bar 345 345 speed max continuous at full stroke rpm 2100 1800 consult DENISON HYDRAULICS for higher speeds flow ports A or B 1500 159 7 198 7 theo at max displ Lpm 604 6 752 1 at 1800 rpm gpm 191 7 238 4 Lpm 725 5 902 5 at2100 rpm 223 6 Lpm 846 24 eaux pump theor displ rev 2 81 2 81 cc rev 46 1 46 1 P24S P30S 1 05 1 05 cc rev 17 2 17 2 P24P P30P flow auxiliary pump at 1500 rpm gpm 18 2 18 2 internal theo flow Lpm 69 1 69 1 at 1800 rpm gpm 21 9 21 9 Lpm 82 9 82 9 at 2100 rpm 25 5 5 Lpm 96 7 P24S P30S at 1500 rpm 6 5 6 5 Lpm 24 5 24 5 at 1800 rpm gpm 7 8 7 8 Lpm 29 5
26. large spline end first into counterbore in face of barrel and engage barrel spline Slide holddown spring assembly 3 onto shaft 2 Install spring retainer 4 into counterbore Thread holddown screw assembly 5 into barrel s counterbore approximately four threads Tilt barrel vertically and engage main shaft spline with the barrel spline allo wing barrel to drop in place Thread holddown screw assembly 5 into counterbore until it is 25 in 6 35 mm belo w barrel face PARTS LIST FOR FIGURE 4 1 P30 OT at description mmm 1 035 71713 spring retainer 1 523 12171 See figure 5 Clean housing 1 and position on a flat surface with the large open end up Apply Loctite primer grade T amp Loctite retaining compound 609 per A P 01433 to bearing O D amp bearing bore of housing Immediately align amp press bearing into hous ing bore with a smooth steady force until seated Install socket head cap screw 3 with washer 7 Typical two places Torque to 30 Ibs ft 40 8 Nm through drive SAE BB S23 17449 0K PSP es T Trough p drive shaft amp couping 52817448 0 x Ta e f e E m Fem a sess E Install two dowel pins 4 in the blind holes in the control cover pads Repeat step above on the opposite side of the housing Install o ring 5 and plug 6 in the bottom of housing PARTS L
27. of two steps previous Place dual relief poppet 31 over these springs Position seats 28 with the groove side facing up over poppets Place spring 32 into bore next to compensator valve side of block Install replenish poppet over spring Position seat 28 with the groove side facing down over poppet Insert spring 35 into the remaining bore Place spring retainer 34 in spring Place servo poppet 31 over the retainer and spring Position seat 28 with the groove side facing down over poppet Carefully position the retainer plate over seats and poppets Pressing with one hand on the valve compress seats poppets and springs far enough to alternately thread two button head cap screws 43 in far enough to hold the retainer plate Install the other two screws and alternately tighten screws Torque to 30 Ibs in 3 39 Nm Lubricate o ring 4 and install on to seat 5 thread seat in v alve block Be careful not to damage bore in the seat Torque to 15 Ibs in 20 34 Nm Apply vaseline to shank of cone 13 and install spring 12 on cone Carefully insert cone and spring into valve block positioning point of cone into bore of seat Lubricate o ring 11 install in groove of piston 10 and insert end of piston into spring 12 Lubricate o ring 9 and install on housing guide 8 and thread into v alve block Tighten in place Thread nut 7 on socket set screw 6 and thread screw into housing guide 8 until it starts
28. 1 AUX PUMP SERVO REPLEN AGERER CASE DRAIN B SAE INVOLUTE SPLINE DATA J498 B 1969 SS in ds US ag 4 ELAT ROOT SIDE FIT EXTERNAL CLASS gt 071 DGA BEE 97 0 30 PRESSURE ANGLE Se NOTES 88 1 NOTES 22 3 m 1 9710 1 9660 50 063 49 936 MAJOR DIA 23 05 1 REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS 22 3 48 5 585 5 1 VIEWED FROM SHAFT END i 7 2 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 606 8 7 EH DIA 814 i CASE OVERFLOW PORT FOR SUBMERGING 2 PLACES NEAR SIDE amp FAR SIDE y DETAIL A pasa eS BASIC 30 CIPR B MOD V V PUMP Re WITHOUT CONTROLS SAE 2 00 DIA 6000 PSI 1 50 50 8 414 bar SAE F 4 BOLT MOUNTING 2 oan DEEP 4 BOLT FLG CONN 44 www comoso com INSTALLATION DRAWING FOR DIMENSIONS 8 PORT IDENTIFICATIONS NOT SHOWN SEE INSTALLATION 23 9913 D 23 83 605 3 23 15 5 5 le 18 4 6 1 36 34 5 F OPTIONAL REAR AUX MTG SAE C 2 4 BOLT q PORTS G amp K FOR DIMENSIONS 8 PORT IDENTIFICATIONS NOT SHOWN SEE INSTALLATION 23 9913 D 23 05 585 5 P 23 83 ei 605 3 1 66 1 58 42 2 40 2 18 t 46 21 8 COUPLING LENGTH SEALING O RING ARP 159 REF gt UN 5 004 5 003 127 10 2811 1208 127 08 COUPLING DEPTH 86 COUPLING LENG
29. 1 into bore in port block over auxiliary shaft and seat at bottom of bore With the valve block face of the port block located at 12 o clock position the dowel pin hole for vane cartridge assembly 2 in the port block is located between 1 o clock and 2 o clock position Grease o rings on vane cartridge assembly Install vane cartridge assembly into port block making sure dowel pin in vane cartridge assembly to seat against sealing washer 1 NOTE Distance from end of vane cartridge assembly to face of port block 82 0 02 20 8 0 05mm Untie cords holding port plate and remove Apply a light film of oil or grease to o rings 3 4 and tetraseals 5 and place o rings 3 and 4 around pilot of end co ver 6 place tetraseals 5 in grooves in face of end cover Apply a light film of oil or grease to o ring 11 and place on plug 10 Thread plug into end cover and tighten Engage pilot of end cover into bore of port block Refer to figure 10 for G port positioning Align holes and secure with screws 7 Torque to 350 Ibs ft 474 6 Nm Apply a light film of oil or grease to o ring 8 and place on plug 9 Thread plug into end cover and tighten Apply a light film of oil or grease to o ring 21 and place on plug 20 Thread plug into gage port www comoso com ASSEMBLY PROCEDURE Valve block ass y See fig 12 13 6 G port outlet position See figure 13 for its mtg screws To
30. 24 SERIES See figure 4 Install auxiliary shaft 2 large spline end first into counterbore in f ace of barrel spline D s Install spherical seat 3 round or spherical face up into counterbore in face of barrel 7 E Install spring retainer 4 socket side down into counterbore install spring 5 and seat against spring retainer B Thread holddown adjusting screw 6 into counterbore approximately four threads O Tilt barrel vertically and engage main shaft spline with the barrel spline allo wing barrel to drop place Thread holddown adjusting screw 6 into counterbore until it is flush to 0 060 1 52 mm maximum below barrel face PARTS LIST FOR FIGURE 4 P24 through drive arrel amp sleeve assembly S23 12091 auxiliary drive shaft 33 57257 no through drive PT quantity item El auxiliary drive shaft amp coupling 823 17444 0 1 5 1 5 7 part no P24 b 1 SECH x BB S23 17448 h justi h j s PY SAEC S25 4174460k PFS ED 825 17450 0K 5 spring 6 holddown adjusting sorew 033 57139 7 hoiddown adi screw ock 03357241 8 hokiownlockretamingrg 03557299 0 0 033 57138 spring o 0 FIGURE 4 19 www comoso com BARREL AND AUXILIARY DRIVE SHAFT 30 SERIES FIGURE 4 1 HOUSING ASSEMBLY 20 ASSEMBLY PROCEDURE See figure 4 1 Install auxiliary shaft 2
31. Ang Mo Kio Ave 10 Unit 07 01D Techplace Singapore 569628 Tel 65 268 7840 Fax 65 268 7847 Taiwan Denison Hydraulics LTD 6F 10 No 79 Sec 2 Roosevelt Rd Taipei Taiwan ROC Tel 886 2 23645101 Fax 886 2 23639025 Austria Denison Hydraulics GmbH Zweigniederlassung Linz Haibachstraf e 69 4061 Pasching Austria Tel 43 72 29 48 87 Fax 43 72 29 6 30 92 Benelux Denison Hydraulics Benelux B V Pascalstraat 100 3316 GR Dordrecht Holland Tel 31 78 6543 070 Fax 31 78 6175 755 Denmark Denison Hydraulics Denmark A S Industrikrogen 2 2635 Ish j Denmark Tel 45 4371 15 00 Fax 45 4371 15 16 Finland Denison Lokomec Oy Polunm enkatu 22 P O Box 116 33721 Tampere Finland Tel 358 3 357 5100 Fax 358 3 357 5111 France Denison Hydraulics S A 14 route du bois blanc BP 539 18105 Vierzon France Tel 33 2 48 53 01 20 Fax 33 2 48 75 02 91 Great Britain Denison Hydraulics UK LTD Kenmore Road Wakefield 41 Industrial Park Wakefield WF2 OXE West Yorkshire England Tel 44 1924 826 021 Fax 44 1924 826 146 Germany Denison Hydraulics GmbH Auf dem Sand 14 D 40721 Hilden Germany Tel 49 0 2103 940 3 Fax 49 0 2103 940 558 Italy Denison Hydraulics Srl Via Le Europa 68 20090 Cusago MI Italy Tel 39 02 90330 1 Fax 39 02 90390694 5 6 Denison Calzoni S p A Via Caduti di Sabbiuno15 17 40011 Anzola del
32. CONTROL PUMP PUMP CONTROL PRESSURE TO MANUAL OVERRIDE PORT PORT OPTION PACKAGE ROT PORT X PORT Y SHAFT ROTATION A B 24 OR P30P WITH 242 CONTROL mm cw MAX VOLUME MIN VOLUME ccw INLET OUTLET WITH INTERNAL CARTRIDGE SPRING Ccw MIN VOLUME MAX VOLUME cw INLET OUTLET CW CCW ROTATION SAE F 4 BOLT MTG OFFSET P30P cw TO ZERO CCW 23 9934 2012 48 WWW comoso com INSTALLATION DRAWING 8 14 206 8 4 eN TRIMMER ADJ NOTES 1 FOR DIMENSIONS amp PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS 23 9913 D 2 REFERENCE TO PUMP ROTATION R CW 8 L CCW IS AS VIEWED FROM SHAFT END 3 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS m 9 eg H H YE i 2 DEEP 6 4 1 4 20 UNC TAP x MAX VOL STOP 2 VOL STOP 72 EW A A 513 X CONTROL PORT Y CONTROL PORT 508 MAJOR DIA KNURL SAE 4 STR THD SAE 4 STR THD
33. Ga DIA 07 bar ARTIAL VIEW SAE 4 STA THD NEAR SIDE 4 BOLT FLG CONN P S 31 L am SIDE AUX PUMP SERVO amp REPLEN SUPPLY INLET H1 SAE 12 STR THD 7 9 77 0 AUX PUMP SERVO amp REPLEN 2 INLET FROM EXTERNAL FILTER EE PARTIAL VIEW A A DG SAE 6 STR THD CASE GAUGE 1 06 24 70 2629 DA THRU 6275 FB SAE 6 STR THD NEAR SIDE 2 00 19 08 FAGSAE S THD SIDE AG1 SAE 6 STR THD 08 DIA SFACE x DEPTH SHOWN FAR SIDE e 484 7 CONTROL PRESSURE GAGE TEMP GAGE 8 4 PLACES 17 66 15 5 347 448 5 4 m 52 341 10 92 158 0 158 0 4 SEE APPROPRIATE SEE APPROPRIATE 88 1 277 5 BG1 SAE 6 STR THD B CONTROL INSTL CONT ROG INST 86 6 ai 2 SYSTEM B GAGE 5 55 5 55 ro 86 6 UE REFS 141 0 141 0 form om 1 i ER 2 9 1 Poo 6 81 173 0 FULL 1 75 re ee g Sie Ts SPLINE 44 4 605 EN 185 7 154 4 6 24 FB REF FA REF 185 7 154 4 158 6 837 i 6 37 161 8 128 5 44 5 D VB amp VA 1 9 75 mi 2 1 as LO E H 1 Y Y 247 6 L q 098 Di 1 i y 59 6 998 A 177 80 0 1 6 18 Ly 3 30 1457 0 83 7 4 87 17755 157 0 4 75 83 7 i 0123 7 TYP 120 7 7 31 6 10 1 154 9 185 7 42 ago AG2 amp BG2 REF 30 i 1 38 1 85 0 SCH LA L at D D Edd D2 SAE 20 STR THD
34. I BG2 SAE 8 STR THD 1 999 N 644 SYSTEM B GAGE 1998 pia 1636 50 77 a 50 75 ads 105 9 i 4 158 1 53 42 2 3 y 1 1 175 77 7 2 218 jum 4 20 44 4 1 92 25 106 7 56 18 23 4 Ga 6 44 163 6 12 1 3 0 AG2 SAE 8 STR THD de SYSTEM A GAGE 46 x 45 t 1 5 78 252 KG SAE 6 STR THD REPLENISHING GAUGE E 4 etum oe PARTIAL VIEW B B 66 3 66 6 VB SAE 4 STR THD NEAR SIDE 4 BOLT FLG CONN a L am VA STR THD FAR SIDE AUX PUMP SERVO amp REPLEN H1 SAE 12 STR THD 7 9 77 0 POR MENE SUPPLY INLET AUX PUMP SERVO amp REPLEN um INLET FROM EXTERNAL FILTER H2 REF PARTIAL VIEW A A DG SAE 6 STR THD CASE GAUGE 1 06 23 70 268 Din THRU H 6021 FB SAE 6 STR THD NEAR SIDE FA SAE 6 STR THD FAR SIDE 2 00 DIA SFACE x DEPTH SHOWN FAR SIDE 18 08 CONTROL GAGE AG1 SAE 6 STR THD 50 8 4 PLACES EIA 1666 4599 SYSTEM A GAGE 15 5 __ SEE APPROPRIA m 341 m cae m SEE APPROPRIATE 8817 277 5 BG1 SAE 6 STR THD 0589 mo B CONTROL INSTL 86 6 T SVETEM D GAGE S i 22 mes 866 He REF 141 0 141 0 i 36 T 9 1 IC 6 81 1 75 173 0 FULL 173 KG 7 31 wass n 185 7 158 6 285 AN WN FA REF 161 8 gt QD O 1 E gt 9 75 ud 8275
35. Standard controls for the Goldcup units are rotary servo and compensator over ride Additional optional controls are also available This pump is designed to operate in any position The mounting hub and 4 bolt mount ing flange are in full conformance with SAE standard The pump shaft must be in align ment with the shaft of the prime mover and should be checked with a dial indicator The mounting pad or adapter into which the fluid pump pilots m ust be concentric with the pump shaft to prevent bearing failure This concentricity is particularly important if the shaft is rigidly connected to the prime mover without a flexible coupling Caution P24 30S Only Shaft seal on coupling shaft isolates inter nal replenishing pressure from the external pump An axial load in pounds equal to 1 23 x replenishing pressure psi or Newtons equal to 79 3 x replenishing pressure bar will be exerted on the shaft of the rear mounted pump Shaft bearing capacity of the external pump must be considered when applying external pump In any application it is advisable to check the alignment of the pump shaft to the pr ime mover to avoid side loading the pump shaft bearing and bending of the shaft The maximum allowable offset of the pump shaft and prime mover is 0 006 inch 0 15 mm T I R Total indicator reading The maximum allowable angular misalignment is 3 002 inch per inch radius 0 002 mm per mm radius Splined The coupling interface must be lubricated
36. and creep plate 5 from the rocker cam 21 Remove the four screws 11 and four screws 12 from the control chamber covers 13R and 13L Remove the control chambers 14 Remove the seals 17 four steel balls 16 and dowel pins 15 Remove the screw 3 vane seal cartridges 23 holddown vanes 22 from the rocker cam 21 Remove the rocker cam from the cradle 18 wear part max rework from min dimension original dimension after rework port plate face 0 010 0 254 mm 0 735 18 67 mm shoe retainer face 0 005 0 127 mm 0 494 12 55 mm creep plate face 0 010 0 524 mm 0 365 9 27 mm face plate none replace No rework allowed on 30 in piston shoe face www comoso com REWORK LIMITS OF WEAR PARTS continued 14 UNIT DISASSEMBLY IMPORTANT The port plate finish must be 8 microinches 0203 micrometer both faces flat within 0 00006 0 0015 mm and parallel within 0 001 0 0254 mm total indicator reading The creep plate wear face finish must be 5 microinches 0127 micrometer flat within 0 0005 0 0127 mm and parallel to the backside within 0 001 0 0254 mm total indica tor reading The shoe retainer wear face finish must be 32 microinches 0813 micrometer and flat within 0 0005 0 0127 mm Must not be convex The piston shoes wear face finish must be 30 microinches 0762 micrometer and must be lapped in a set with the retainer plate all shoe sole thicknesses
37. comoso com CONTENTS technical characteristics fluid connections seal kits introduction description mounting rear pump mounting shaft information piping recommended fluids viscosity viscosity index temperature alternate fluids fluid cleanliness comparison of solid contamination classification system filling case service information maintenance start up procedures for new installations trouble shooting assembly tool drawings T1 T2 T3 and T4 disassembly procedures rework limits of wear parts assembly procedures figure 1 shaft and bearing assembly figure 2 rocker cam piston shoes amp retainer cam and cradle assemblies rocker cam piston and shoe figure 3 mounting flange cam amp cradle barrel amp auxiliary shaft figure 4 barrel and auxiliary drive shaft 24 series figure 4 1 barrel and auxiliary drive shaft 30 series figure 5 housing figure 6 housing end cap cam and barrel mechanical shaft seal figure 7 seal assembly counter balance plate servo plate control cover figure 8 port block port block installation figure 9 barrel holddown and auxiliary pump 24 series barrel holddown and auxiliary pump 30 series auxiliary pump and end cover figure 10 rear drive adapter and shuttle valve rear drive adapter pilot valve shuttle valve figure 11 exploded view of shuttle valve and pilot valve ext drain shuttle valve adapter shuttle valve mounting valve block assembly figure 12 valve block assembly valve block for servo valve
38. face plate 2 and face plate pins 1 from the face of the barrel assembly See figure 4 Remove holddown adjusting screw lock 7 use an 18 blade type screwdriver with the blade ground down to clear holddown shaft See figure 7 Lock main shaft from turning See figure 4 Use special tool T2 slip over auxiliary shaft 2 and engage dowels into holddown adjusting screw 6 Loosen load but do not remove See figure 6 Remove two bolts 5 holding housing and flange together See figure 3 Push tubes 4 out of housing slots and to ward barrel do not bend or damage them See figure 6 Lift housing 4 over tubes and barrel assembly and remove Mounting flange must be driven from housing due to tight fit NOTE Do not damage gasket faces in this process Do not remove the retaining screws or bearing from the housing unless bearing is damaged and replacement is necessary Barrel assembly can be removed by lifting with auxiliary shaft The pistons will remain with the cam assembly These parts are precision finished and must be handled with extreme care See figure 4 Using special tool T2 holddown assembly can be removed from barrel Remove adjusting screw 6 spring 5 retainer 4 spherical seat 3 and auxiliary shaft 2 See figure 9 Remove four screws 1 and two screws 8 NOTE There is a preload from the barrel holddown which will lift the port block approximately 1 8 3 2mm at release Carefully lift and re
39. into holddown adjusting screw Torque to 30 Ibs ft 40 7 Nm Slip holddown lock retaining ring 8 figure 4 over auxiliary shaft into groove which is located 5 3 4 146 05 mm from end of shaft 25 www comoso com BARREL HOLDDOWN AND AUXILIARY PUMP 30 SERIES AUXILIARY PUMP END COVER 26 ASSEMBLY PROCEDURE See figure 4 1 amp 10 Use special tool T2 and slip over auxiliary shaft and engage dow els into holddown screw assembly 5 figure 4 1 Carefully tighten clockwise until hold down screw assembly bottoms out NOTE The main drive shaft must be held to prevent barrel assembly from turning If barrel assembly turns the adjustment cannot be made Back off holddown screw assembly 140 counter clockwise Barrel lift off is now set at 0 032 0 81mm Remove spanner wrench Rotate drive shaft to check if any binding occurs Lock holddown screw assembly in place by tightening the six socket head cap screws gradually in the following torque sequence until 65 7 4 Nm torque is reached NOTE If barrel holddown has to be reset for any reason all six socket head cap screws must be loosened gradually in the same order they were tightened Do not remove screws completely Use the 10 32 UNF threaded holes in the insert to disengage insert from holddown screw assembly Insert must be loose before resetting barrel holddown Torque sequence for locking holddown screw assembly See figure 10 Slip sealing washer
40. kW Pump output flow Lpm Fluid motor speed rpm min tr mn Fluid motor torque Nm Fluid motor power kW 65 CONVERSIONS amp FORMULAS in rev x 16 387 cm rev gpm x 3 78 L min hp x 0 7457 kW lb ft x 1 3567 Nm Ibs in psi x 0 06895 bar lbs in psi x 6 895 kPa lb x 0 4536 kg lb x 4 4482 in x 16 387 cm in x 6 452 cm in x 25 42 mm degree F 32 C 1 8 CSt x 1 0 mm sec SSU cSt x 4 25 14 pressure psi x displacement in rev 2n x mech rpm x x psi 395934 x overall eff rpm x in rev x volumetric eff 231 cm rev x 0 06102 in rev L min x 0 2642 gpm kW x 1 341 hp Nm x 0 7376 Ib ft bar x 14 50 Ibs in psi kPa x 0 1450 Ibs in psi kg x 2 205 Ibs N x 0 2248 Ibs cm x 0 06102 in cm x 0 1550 in mm x 0 03937 in 1 8 x C 32 F mm sec x 1 0 cSt 20 cSt 99 SSU 231 x flow rate U S gpm x volumetric eff displacement in rev pressure psi x displacement x mech eff 2 rpm in rev x psi x overall eff 395 pressure bar x displacement cm rev 20x x mech eff rpm x cm rev x bar 600000 x overall eff rpm x cm rev x volumetric eff 1000 1000 x flow rate Lpm x volumetric eff displacement cm rev pressure bar x displacement cm rev x mech eff 20 rpm x cm rev x bar x overall eff 600000 WWW comoso com Printed
41. pump 24 series 150 psi min 10 3 bar 30 series 225 psi min 15 5 bar Internal vane pump 10 254 mm Hg to 5 psi 0 34 bar Case pressure 55 75 psi 3 8 5 2 bar e xcept S pump Fluid 200 SSU at 100 F 46 cSt at 40 C WWW comoso com BASIC PUMP TEST CONTROL TEST 39 TEST PROCEDURE Mount pump on test stand Connect system lines and internal vane pump inlet to pump Fill pump case with clean oil Dry all oil from pump to per mit checking for external leaks Start electric motor Jog several times before continuous running Rotate pump input control shaft The servo control should control pump displacement through its full range Set pump displacement for full volume and adjust system pres sure for 1000 psi 69 bar Check and record system flow and case drain flow with cam above and below center Monitor loop temperature Maximum system flow 24 series 194 gpm 734 Lpm 30 series 241 gpm 912 Lpm Maximum case drain flow 24 series 4 5 gpm 17 Lpm 30 series 5 5 gpm 21 Lpm Back out compensator adjusting screw until unit is fully compensated count number of turns Observe volume indicator and stroke rotary servo input shaft from full to full position on each side of center Indicator should remain on or very near zero position 0 If compensator functions normally return compensator adjusting screw to its original position and proceed with next step Caution Do not over tighten cap screw Cycle pump at 10 se
42. seal cartridges by rotating the chambers until they slip over the vane seal cartridges then rotate in the opposite direction until the 3 8 dowel pin holes in the chambers align with the do wel pin holes in the rocker cradle 18 Install dowel pins 15 through the control chambers and into the cradle Install chamber covers 13R and 13L on the control chambers 14 The covers must be installed with the override tube 24 holes at the top Note the marks made during disassembly to indicate the top of the rocker cam and cradle NOTE Two sets of control chamber covers are available The set marked CW must be installed in the right hand rotation pump and the set marked CCW must be installed in the left hand rotation pump Rotation is determined from the shaft end of the unit Install two 1 2 13 hex head cap screws 11 in each side Torque to 75 Ibs ft 101 75 Nm Install two 3 8 16 hex head cap screws 12 in each side Torque to 30 Ibs ft 40 7 Nm Install o ring 19 and hex socket plug 20 in each chamber cover Install override tubes 24 in holes in each cover These tubes must be a tight fit If tubes are loose the ends may be expanded with a tapered punch Tap the tubes in place with a plastic mallet Thread two orifice plugs 7 into servo stem 6 Determine the proper location of the ser vo plate and stem Looking at the projecting center post of the rocker cam with the override tube holes at the top locate A mou
43. the six poppet valves bores up in order to press two roll pins 26 in position Roll pins to be 12 3 04 mm below surface of valve block Not required after 8 96 Install four orifice plugs 3 into valve block 1 and tighten in place Disassemble the strainer assembly 14 and reassemble per the following steps Install the orifice screw of the strainer assembly into valve block Thread elastic stop nut onto the orifice screw and torque to 23 Ibs in 2 6 Nm Install clean filter screen on strainer support and secure in place with socket head cap screw 6 32 X 1 4 Ig Torque 6 32 screw to 13 Ibs in 1 47 Nm Place valve block with poppet valve bores facing up Position gasket 29 on valve block Place springs 33 1 43 36 32 mm lg into outer most bores at each end of the v alve block Place sequence poppet 30 over these springs Position seats 27 small shoulder side first over poppets Place springs 35 1 09 27 68 mm lg into bores next to the sequence poppet valves of two steps previous Place dual relief poppet 31 over these springs Position seats 28 with the groove side facing up over poppets Place spring 32 1 56 39 6 mm into bore ne xt to compensator valve side of block Install replenish poppet over spring Position seat 28 with the groove side facing down over poppet Insert spring 33 1 43 36 3 mm into the remaining bore Place servo poppet 34 over the retainer and spring Position sea
44. to 120 Ibs ft 163 Nm CAUTION Exercise extreme care to prevent damage to the valve mounting surface while installing and torquing the top bolts WWW comoso com ASSEMBLY PROCEDURE PARTS LIST FOR FIGURE 9 item description parno quantity hex hd cap screw PoP 30640250 port block assy w shuttle S 823 15127 A ss TF port plate go 0355137 5 housing assembly 24 82512566 1 rousing assembly 307 55512175 hex hd cap screw 30640022 9 washer hdn 51 350 10136 8 9 FIGURES FIGURE 9 BARREL HOLDDOWN See figure 4 amp 10 Use special tool T2 and slip over auxiliary shaft and engage the 24 SERIES holes in the holddown adjusting screw 6 figure 4 Carefully tighten until screw bottoms out NOTE The main drive shaft must be held to prevent barrel assembly from turning If barrel assembly turns the adjustment cannot be made Remove special tool T2 and sight through holddown screw and note where tooth of auxiliary shaft spline is located Back off holddown screw loosen 5 to 6 spline teeth on auxiliar y shaft approx 135 NOTE Tapped hole in holddown screw must line up with space between spline teeth Barrel lift off is now set at 030 036 76 91 mm Use a large screw driver with the sides of the blade ground down so it passes along side the aux shaft and engages the screw slot Thread holddown adjusting screw lock 7 figure 4
45. 00000 particles 15um 32 64 130 250 500 1000 2000 4000 8000 16000 32000 64000 130000 250000 500000 NOTES All measurements are for a 100 ml sample size WWW comoso com FILLING CASE SERVICE INFORMATION MAINTENANCE START UP PROCEDURES FOR NEW INSTALLATIONS INSTALLATION It is essential to make certain that the case pump housing is as full of fluid as possi ble 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 Recommended fill points Mounting orientation vertical shaft up D1 or D2 drain port in housing Vent DG2 port in mounting flange new units or one of the upper screws which attach the con trol See installation drawing Vertical shaft down or horizontal drain ports to the side D1 or D2 drain port in housing 1 Vent DG case gage port in port block These hydraulic products are designed to give long dependable service when properly applied and their systems properly maintained These general instructions apply to typ ical systems Specific instructions for particular equipment can be developed from them This pump is self lubricating and preventative maintenance is limited to keeping sys tem fluid clean by changing filters frequently Keep all fittings and screws tight Do not operate at pressures and spee
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47. 1 2M6 02 2N6 02 748 01 02 8C8 00 2 6 403 2 6 03 5 6 00 03 8C8 01 9C6 00 2M6 04 2N6 04 5C6 01 7K6 01 04 8C8 02 9 6 01 2 6 05 2 6 05 01 8C8 03 2 6 06 2 6 06 5C7 00 7K8 01 8A8 00 9C7 00 2M6 07 2N6 07 5C7 01 8A8 01 9C7 01 8 8 02 2 7 00 2N7 00 5C8 00 8 8 03 9C8 00 2M7 01 2N7 01 5C8 01 8A8 04 9C8 01 2M7 402 2 7 02 2 7 403 2N7 03 2 7 04 2N7 04 2M7 05 2N7 05 e Unless otherwise specified on purchase order the following 2M7 06 2N7 06 factory setting will be used 2 7 07 2 7 07 Maximum Stop Full Displacement Minimum Stop Zero Displacement Pressure Compensator Override 5000 psi 2 8 00 2N8 00 Torque Limiter 4 P6 1800 rpm 60 hp 2M8 01 2N8 01 P7 1800 rpm 72 5 hp P11 1800 rpm 110 hp P14 1800 rpm 140 hp P24 1800 rpm 240 hp P30 1800 rpm 300 hp 64 www comoso com DEFINITION amp UNIT displacement flow power torque pressure weight force volume area length temperature viscosity FLUID POWER FORMULAS Pump input torque lbs Pump input power hp Pump output flow 0 5 Fluid motor speed r pm Fluid motor torque lbs in Fluid motor power hp metric Pump input torque Nm Pump input power
48. 1 2 13 UNC x BASIC 30 CIPR B MOD V V PUMP WITH SAE B or SAE C AUX REAR MTG W O CONTROLS SAE F 4 BOLT MOUNTING 23 9919 Y VOLUME ADJ SEE CHART INSTALLATION DRAWING CONTROL PUMP FIND PUMP ROTARY SERVO INPUT PORT PORT agi aye OPTION PACKAGE FIGURE ROT spRG OFF SET TO FULL A gr X VOL ADJ Y VOL ADJ j 5 2 2 Cw CCW ROT FULL TO MIN INLET OUTLET VOLUME STOP MIN VOLUME STOP 402 P30P 2 CCW CW FULL TO MIN INLET OUTLET MIN VOLUME STOP MAX VOLUME STOP FIGURE 2 1 4 20 UNC 25 DEEP 7 6 4 45 11 4 Lu S 8 51 8 55 16 1 217 2 SEE MANUAL OVERRIDE DETAIL 513 508 MAJOR DIA KNURL 189 82 TEETH PER INCH 12 90 MANUAL OVERRIDE SHAFT DETAIL NOTES FOR DIMENSIONS amp PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS 23 9913 D VIEWED FROM SHAFT END e
49. 13 03 32 TEETH PER INCH 2 90 MANUAL OVERRIDE SHAFT DETAIL TO OPERATE DISCONNECT OIL SUPPLY TO CONTROL PORTS SCALE NONE A i 8 55 i 217 2 l Sp e l OO x KO M ats Ht 9 i 1 i fr A CONTROL MTG POSITION CONTROL PUMP PUMP CONTROL PRESSURE TO MANUAL OVERRIDE PORT PORT OPTION PACKAGE ROT CONTROL PORT SHAFT ROTATION A B P24P OR P30P WITH 2H2 CONTROL cw GOW OUTLET INLET WITH INTERNAL CARTRIDGE Su Y ew mE CW CCW ROTATION SAE F 4 BOLT MTG P30P cw cw INLET OUTLET ccw x INLET OUTLET 23 9926 1012 49 WWW comoso com INSTALLATION DRAWING NOTES FOR DIMENSIONS amp PORT IDENTIFICATIONS SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS 23 9913 D REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS VIEWED FROM SHAFT END DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 14 20 UNC 25 DEEP 6 4
50. 29 5 P24S P30S flow auxiliary pump at 1500 rpm gpm 18 2 18 2 external standard T6C 025 Lpm 69 1 69 1 at1800rpm gpm 21 9 21 9 Lpm 82 9 82 9 P24P P24S P30P P30S eaux pump servo pressure range psi 340 640 490 790 360 772 490 902 varies upward with pressure in bar 23 44 34 54 25 53 34 62 port A or B based on 0 psi 0 bar case pressure P24P P24S P30P P30S Aux pump replenishing pressure psi 180 220 330 370 180 220 330 370 based on 0 psi 0 bar case pressure bar 12 15 23 26 12 15 23 26 mounting SAE 177 4 177 4 F 4 bolt F 4 bolt eshaft spline or keyed SAE 50 1 4 50 1 4 F eweight P24P P24S P30S lbs 690 755 710 787 kg 313 342 322 357 R 4 O oils rust and oxidation inhibitor Standard other sizes available Internal cartridge provides servo flow and must be supercharged from external replenishing flow from external auxiliary pump Any SAE 82 2 or SAE 101 2 mounting pump may be used with the corresponding adapters www comoso com SEAL KITS FLUID CONNECTIONS Refer to page 40 for specifications SEAL KITS seal kit P24 30 complete includes control seals see chart below valve block seal kit all 823 17338 shaft seal kit shaft seal controls seal kit all input amp output see chart below 623 00015 5K 523 17000 Seal Kits P24 30 Gold Cup Pumps SHAFT ROT COMPLETE SHUTTLE SHAFT SEAL KIT TYPE SEAL KIT 523 18006 323 18016 9K 523 11516
51. 4S P30S w servovalve adapter 8 on off compensator control FIGURE 13 36 www comoso com GENERAL REQUIREMENTS BASIC PUMP TEST 37 TEST PROCEDURE Maximum runout between pump shaft and electric motor shaft 003 076 mm total indicator reading Electric motor speed 1800 rpm Inlet temperature 120 140 F 500 580C Inlet condition main pump 24 series 150 psi min 10 3 bar min 30 series 225 psi min 15 5 bar min internal vane pump 10 Hg to 5 psi 254 mm Hg to 34 bar e xcept S version Case pressure 55 75 psi 3 81 5 19 bar Fluid 200 SSU at 100 F 46 cSt at 40 C Mount pump on test stand Connect system lines and internal externial with auxiliary drive vane pump inlet to pump Fill pump case with clean oil Dry all oil from pump to permit checking for external leaks Start electric motor Jog several times before continuous running Rotate pump input control shaft The servo control should control pump displacement through its full range Set pump displacement for full volume and adjust system pres sure for 1000 psi 69 bar Check and record system flow and case drain flow with cam above and below center Monitor loop temperature Maximum system flow 24 series 194 gpm 734 Lpm 30 series 241 gpm 912 Lpm Maximum case drain flow 24 series 4 5 gpm 17 Lpm 30 series 5 5 gpm 21 Lpm Back out compensator adjusting screw until unit is fully compensated count number of turns Observe volume indic
52. 8 14 206 7 www comoso com SOLENOID VALVE B 8 14 SOLENOID VALVE A MAX VOL STOP TRIMMER ADJ MAX VOL STOP TRIMMER ADJ LOCK A 8 55 m 10 32 as 217 2 262 1 d P24P OR WITH 9A2 CONTROL WITH INTERNAL CARTRIDGE CW CCW ROTATION SAE F 4 BOLT MTG 23 9920 1012 NOTES INSTALLATION DRAWING FOR DIMENSIONS A PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS 23 9913 D REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS VIEWED FROM SHAFT END DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS E 19 RECESS 12 DEEP 4 8 3 MATING DIN 43650 TYPE AF TWO 2 SUPPLIED WITH CONTROL MANUAL OVERRIDE SHAFT DETAIL MAX VOL STOP TRIMMER ADJ LOCK SCALE 4X TRIMMER ADJ 2 9 27 gt 55 MAX VOL STOP 235 4 14 0 SOLENOID VALVE A SOLENOID VALVE B CON
53. AFT ROTATION A B cw CCW INLET OUTLET T dr ccw P2 cw INLET OUTLET P30S cw P2 cw OUTLET INLET CCW OUTLET INLET 58 je D3 DRAIN CONN SAE 16 STR THD KA SHUTTLE RELIEF INLET SAE 12 STR THD P24S OR P30S WITH 8A2 CONTROL amp T6C AUX PUMP WITH INTERNAL CARTRIDGE CW CCW ROTATION SAE F 4 BOLT MTG www comoso com 23 9916 INSTALLATION DRAWING NOTES e 18 RECESS x 4 8 FOR DIMENSIONS amp PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS 23 9913 D REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS VIEWED FROM SHAFT END DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 12 8 0 DEEP MANUAL OVERRIDE SHAFT DETAIL SCALE 4X 9 27 235 4 MATING CONNECTOR DIN 43650 TYPE AF TWO 2 SUPPLIED WITH CONTROL 9 A CONTROL MTG POSITION A ra e cw B Ccw OUTLET INLET ccw cw OUTLET INLET P30P cw A cw INLET OUTLET B cow INLET OUTLET 59
54. DENISON HYDRAULICS axial piston pump goldcup series P24P S E mod P30P S B mod service information Publ LT3 00032 2 A 8 03 REGISTERED FIRM www comoso com The product information specifications and descriptions contained in this publication have been compiled for the use and convenience of our customers from information furnished by the man ufacturer and we can not and do not accept any responsibility for the accuracy or correctness of any description calculation specification or information contained herein No such descrip tion calculation specification or information regarding the products being sold has been made part of the basis of the bargain nor has same created or amounted to an express warranty that the products would conform thereto We are selling the goods and merchandise illustrated and described on this publication on an as is basis and disclaim any implied warranty including any warranty of merchantability or warranty of fitness for any particular purpose whatsoever with respect to the goods and merchandise sold All manufacturer warranties shall be passed on to our customers but we shall not be responsible for special indirect inci dental or consequential damages resulting from the use of any of the products or information contained or described on this publication Further we reserve the right to revise or otherwise make product improvements at any time without notification www
55. IST FOR FIGURE 5 desorption pnmo wuammy F ee rg sar bearing 033 93046 5 p a 1 Figure 5 www comoso com HOUSING END CAP CAM AND BARREL ASSEMBLY FIGURE 6 MECHANICAL SHAFT SEAL ASSEMBLY PROCEDURE 21 ASSEMBLY PROCEDURE See figure 6 Install new gasket 3 over the dowel pin in the mounting flange Do not use gasket compound Insert two socket hd cap screws 6 through holes in balance stem 7 Attach balance stem to stroking control assembly Torque to 70 Ibs in 6 6 Nm Install the housing assembly 4 over the barrel and auxiliary shaft assembly Carefully guide the override tubes and pressure feed tubes items 2 and 4 figure 3 through the housing assembly Position the pressure feed tubes in the slots in the housing face NOTE Lightly force the pressure feed tubes downward toward the stroking assembly do not bend or crimp the tubes enough so that they must be pulled up a little to snap into the housing slots This will hold them in position for assembling the port block to the housing Insert two hex hd cap screws 5 through mounting flange and into housing Torque to 100 Ibs ft 135 6 Nm These must be fully torqued later when main bolts are in place Install face plate pins 1 in the holes pro vided in the barrel face Apply clean heavy grease to the surface of the barrel and install the face plate 2 over the face p
56. L MANUAL SERVOVALVE SHUT OFF SHOWN IN OPEN POSITION ROTATE 90 TO SHUT OFF S SERVO VALVE INLET SAE 8 STR THD KG REPLENISHING PRESS GAGE CONN A SAE 6 STR THD rB E O SI 2 55 64 j 8 Y 7 51 190 8 GT UJ P24 30P W 7E2 B CONTROL W WO COMPENSATOR SHUT OFF amp WITH RVDT CW CCW ROTATION SAE F 4 BOLT MOUNTING 23 9923 INSTALLATION DRAWING NOTES FOR DIMENSIONS 8 PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS _23 9913 D N REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS VIEWED FROM SHAFT END DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 1 4 20 UNC TAP x 29 DEEP 6 4 45 11 4 513 508 MAJOR DIA KNURL 18 03 32 TEETH PER INCH 12 90 MANUAL OVERRIDE SHAFT DETAIL TO OPERATE DISCONNECT OIL SUPPLY TO CONTROL PORTS SCALE NONE 1 A CONTROL MTG POSITION CONTROL PUMP PUMP CONTROL PRESSURE TO MANUAL OVERRIDE PORT PORT OPTION PACKAGE ROT SAE 4 STR THD CONTROL PORT SHAFT ROTATION B cw Ccw OUTLET IN
57. LET rae ccw P2 cw OUTLET INLET P30P cw P2 cw INLET OUTLET ccw ccw INLET OUTLET 56 www comoso com P2 CONTROL PORT SAE 4 STR THD P1 CONTROL PORT SAE 4 STR THD MAX VOL STOP TRIMMER ADJ MAX VOL STOP VIEW A A TRIMMER ADJ LOCK P24P OR P30P WITH 8A2 CONTROL WITH INTERNAL CARTRIDGE CW CCW ROTATION SAE F 4 BOLT MTG 23 9915 1012 INSTALLATION DRAWING NOTES FOR DIMENSIONS 8 PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION E P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS 23 9913 D REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS VIEWED FROM SHAFT END DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS N e 1 4 20 UNC TAP x 25 DEEP 7 69 6 4 VIEW A A 513 508 MAJOR DIA KNURL 1303 82 TEETH PER INCH 12 90 TRIMMER ADJ LOCK MANUAL OVERRIDE SHAFT DETAIL MAS VOL STOP TO OPERATE DISCONNECT OIL SUPPLY TO CONTROL PORTS SCALE NONE TRIMMER ADJ MAX VOL STOP 8 64 8 55 219 5 217 2 T H 70087
58. M 285 4 Sp 216 1 CONTROL PUMP em OPTION PACKAGE FIGURE ROT SHAFT ROTATION A PORT gr 5A 1 CW CCW INLET OUTLET P24P 1 CW INLET OUTLET amp P30P 1 Cw Cw OUTLET INLET CCW CCW OUTLET INLET P24P OR P30P WITH 5A2 CONTROL WITH INTERNAL CARTRIDGE CW CCW ROTATION SAE F 4 BOLT MTG 23 9914 INSTALLATION DRAWING 8 14 19 19 206 7 TRIMMER ADJUSTMENT 5 CONTROL MTG POSITION MAX 7 CONTROL PUMP FIND PUMP ROTARY SERVO INPUT PORT PORT MAX VOLUME STOP FIGURE 2 OPTION PACKAGE FIGURE ROT SHAFT ROTATION CW CW INLET OUTLET P24P CW OUTLET 5C2 3 CCW INLET 2 2 P30P 2 Cw CCW OUTLET INLET 2 CCW Cw OUTLET INLET 142 3760 3755 I Z BRAKE ACTUATOR assy D 8 73 SAE 6 STR THD 11 43 8 538 217 290 3 1 1 7 DIA WITH 20 WIDE FLAT VIEW B B 79 B 216 1 285 2 NI 5 SERVO INLET 7 SAE 4 STR THD 15 D
59. MP SERVO amp REPLEN INLET FROM EXTERNAL FILTER 10 91 277 1 287 3 Y NOTES 1 FOR DIMENSIONS 8 PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION D P24P BASIC INSTALLATION LESS CONTROLS _23 9922 D B CONTROL MTG POSITION P30P BASIC INSTALLATION LESS CONTROLS _23 9913 D CONTROL PUMP PUMP VOLUME INDICATOR PORT PORT 2 REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS OPTION PACKAGE ROT SHAFT ROTATION B VIEWED FROM SHAFT END cw CCw INLET OUTLET 3 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS P24P ccw cw INLET OUTLET 7 2 amp cw cw OUTLET INLET ccw ccw OUTLET INLET 54 www comoso com S SERVO VALVE INLET KG REPLENISHING PRESS GAGE CONN SAE 6 STR THD VIEW A A OPTIONAL MANUAL SERVOVALVE SHUT OFF SHOWN IN OPEN POSITION ROTATE 90 TO SHUT OFF A P24 30P W 702 CONTROL W WO COMPENSATOR SHUT OFF amp WITH FEEDBACK POTENTIOMETER CW CCW ROTATION SAE F 4 BOLT MOUNTING 23 9928 MATING CONN ECTOR DENISON 721 30018 REF INSTALLATION DRAWING SERVOVALVE ELECTRIC CONNECTOR BENDIX 2 8 4 REF A AS SHOWN AMA DC NOM 1 H B 3T T 2 t 4MA DC NOM
60. RRIDE DETAIL TO OPERATE DISCONNECT OIL SUPPLY TO SERVO S INLET PORT DONOTEXCEED 50065 TORQUE 6 ELEC HYD STROKER ELECTRICAL INPUT INPUT 19 CCW MECHSTOP ELECTRICAL CONN A SEE NOTE 4 re VIEW A A TRIMMER ADJUSTMENT SEE MANUAL OVERRIDE DETAIL 4 1 VOLUME STOP ELECTRICAL CONN T CURRENT AT FULL DISPL A 350 MA NOM COIL RESISTANCE 250 NOM WITH ELECTRICAL POLARITY AS SHOWN cw POLARITY 19 CW INPUT SHAFT WILL ROTATE CCW MECHSTOP FIGURE 1 Se 1 FOR DIMENSIONS amp PORT IDENTIFICATIONS SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS 23 9913 D 2 REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS VIEWED FROM SHAFT END 3 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 4 ELECT RECEPTACLE CONN 5 8 24 UNEF x 290 MATING CONNECTOR HALF MS3106E 10SL 45 9 91 SEE NOTE 4 290 3 B CONTROL MTG POSITION FIND PUMP ROTARY SERVO INPUT PORT 2 S SERVO INLET TRIMMER ADJUSTMENT SAE 4 STR THD WWW comoso com E
61. T FOR FIGURE 13 SERVO VALVE MOUNTING description quantity Figure 13 1 valve block 033 91335 1 continued check valve assembly S13 40266 033 91249 691 00903 033 70508 312 13160 335 13100 033 70545 691 00910 036 21767 671 00012 032 91798 036 12288 13 43240 033 54389 033 54446 225 92083 691 00906 488 35041 691 00904 488 35001 033 54445 488 35049 325 12120 033 70507 033 70500 033 91193 033 72378 033 72379 033 22141 033 70512 033 54398 033 71086 523 12699 671 00050 033 54392 691 00008 358 10180 033 91422 353 25078 033 54399 327 25006 325 08120 671 00013 671 00014 449 00013 358 16360 035 40132 356 31043 691 00011 523 02208 306 40132 033 25528 orifice plug o ring seat Soc hd screw 5 16 24 1 19 hex jam nut 5 16 24 housing guide o ring seal piston o ring spring cone servo strainer assembly manifold manifold servovalve use w 7F or 7G controls spring o ring plug o ring plug spool servovalve use w F or 7G controls plug roll pin sequence seat replenish amp servo seat valve block gasket sequence poppet dual amp replenish poppet replen spring sequence amp servo spring servo relief poppet dual relief spring pilot replen valve o ring spool o ring soc hd screw 10 24 x 1 1 4 Ig retainer plate screw servo relief seat acorn nut 5 16 24 roll pin 1 8 x 3 4 Ig o ring o ring plug 7 16 20 soc hd screw 3 8 16 x 4 l
62. TALLATION DRAWING NOTES FOR DIMENSIONS 8 PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS _23 9922 D P30P BASIC INSTALLATION LESS CONTROLS _23 9913 D REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS VIEWED FROM SHAFT END DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS N B eae H 1 4 20 UNC TAP x22 DEEP 6 4 45 11 4 VIEW A A 513 4508 MAJOR DIA KNURL x 1848 82 TEETH PER INCH 12 90 MANUAL OVERRIDE SHAFT DETAIL N TO OPERATE DISCONNECT OIL N SUPPLY TO CONTROL PORTS x 8 14 SCALE NONE 206 8 g Jl 100 A 1 25 4 100 _ LJ 8 55 s 8 55 25 4 217 2 217 2 d SE unm 7 9 alo 57 e ut balas e GC MIN VOLUME STOP CW PUMP ROTATION MAX VOLUME STOP CCW PUMP ROTATION MIN VOLUME STOP CCW PUMP ROTATION MAX VOLUME STOP CW PUMP ROTATION A X CONTROL PORT 1 8 27 DRYSEAL N P T F Y CONTROL PORT 1 8 27 DRYSEAL N P T F B CONTROL MTG POSITION
63. TH SEALING O RING ARP 155 REF ES OPTIONAL REAR AUX MTG SAE B 2 BOLT 4 002 4 006 101 65 23 05 585 5 NOTES 1 REFERENCE TO PUMP ROTATION R CW A L CCW IS AS VIEWED FROM SHAFT END 2 DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 45 PORTS G amp K 1 WWW comoso com DIA PILOT x 50 pp 12 7 101 75 1 0 5 8 11 UNC x 25 4 EQUALLY SPACED AS SHOWN 2 13 BOLT CIRCLE 4 PLACES 181 0 SAE C INVOLUTE SPLINE DATA J498 B 1969 FLAT ROOT SIDE FIT EXTERNAL CLASS 1 12 24 PITCH 30 PRESSURE ANGLE 14 TEETH 1 2630 1 2500 32 080 31 750 MAJOR DIA 0 DEEP G SAE 12 STR THD AUX PUMP SERVO amp REPLEN OUTLET TO EXTERNAL FILTER A 5 I sp 148 Leer K OPTIONAL SAE 16 STR THD REPLEN SUPPLY INLET SAE B INTERNAL INVOLUTE SPLINE DATA PER J498b 1969 FLAT ROOT SIDE FIT CLASS 1 16 32 PITCH 30 PRESSURE ANGLE 13 TEETH 7583 7533 19 261 19 134 MINOR DIA 1 2 13 UNC x 100 DEEP 25 4 EQUALLY SPACED AS SHOWN 6 38 ON BOLT CIRCLE 4 PLACES 161 9 G SAE 12 STR THD AUX PUMP SERVO 8 REPLEN OUTLET TO EXTERNAL FILTER K OPTIONAL SAE 16 STR THD REPLEN SUPPLY INLET 100 Deep 25 4 EQUALLY SPACED AS SHOWN 5 75 ON BOLT CIRCLE 4 PLACES 146 1
64. TROL PUMP PUMP MANUAL OVERRIDE PORT PORT OPTION PACKAGE ROT ENERGIZE SOLENOID SHAFT ROTATION AY B cw ccw INLET OUTLET P24P ccw B cw 9A2 amp INLET OUTLET cw B cw OUTLET INLET CCW A CCW OUTLET INLET 60 www comoso com VIEWA A P24P OR P30P WITH 9A2 CONTROL WITH INTERNAL CARTRIDGE CW CCW ROTATION SAE F 4 BOLT MTG 23 9920 2012 e INSTALLATION DRAWING NOTES FOR DIMENSIONS amp PORT IDENTIFICATIONS NOT SHOWN SEE THE APPROPRIATE BASIC PUMP INSTALLATION P24P BASIC INSTALLATION LESS CONTROLS 23 9922 D P30P BASIC INSTALLATION LESS CONTROLS 23 9913 D REFERENCE TO PUMP ROTATION R CW amp L CCW IS AS VIEWED FROM SHAFT END DIMENSIONS IN PARENTHESIS ARE METRIC SI UNITS 19 19 HEX RECESS 12 DEEP 4 8 MANUAL OVERRIDE SHAFT DETAIL 8 0 MATING CONNECTOR DIN 43650 TYPE AF TWO 2 SUPPLIED WITH CONTROL TRIMMER ADJ LOCK E TORQUE ADJ SEE CHART
65. UMP ROTARY SERVO INPUT PORT PORT OPTION PACKAGE FIGURE ROT SHAFT ROTATION A ep 1 cw ccw INLET OUTLET 24 CCW OUTLET 5 2 1 C cw INLET P30P 1 cw cw OUTLET INLET SEE MANUAL 1 CCW CCW OUTLET INLET OVERRIDE DETAIL 62 8 j S SERVO INLET SAE 4 STR THD P24P OR P30P WITH 5C2 CONTROL WITH INTERNAL CARTRIDGE CW CCW ROTATION SAE F 4 BOLT MTG 23 9936 MAX VOLUME STOP TRIMMER ADJUSTMENT 53 WWW comoso com MATING CONN ECTOR DENISON 721 30018 REF INSTALLATION DRAWING SERVOVALVE ELECTRIC CONNECTOR BENDIX PC02H 8 4P REF A AS SHOWN MADDC NOM P 1 1 2 4MA DC NOM U p SERVOVALVE WIRING SCHEMATIC POTENTIOMETER ELECTRIC CONN DENISON 721 30079 MODIFIED DENISON 099 13142 MATING CONN a DENISON 721 30059 REF gt woommn gt WIRING SCHEMATIC DENISON 037 44092 11 31 H1 14 12 UNF 37 FLARED TYPE SAE ELBOW AUX PU
66. YED patty Tem description 3 2 0959799 T j 1 03971712 023271910 E E sna earin 23082213 T T 22 SHOWN W SERVO STEM amp PLATE amp 20 ON B SIDE OF UNIT 13R MARK DESIGNATES TOP OF ASSEMBLY FIGURE 2 www comoso com CAM CRADLE ASSEMBLIES items 6 through less item 24 25 figure 2 ROCKER CAM PISTONS SHOES amp RETAINER 16 ASSEMBLY PROCEDURE S23 12478 is for RH CW rotation pumps with B suffix input control on right side S23 12479 is for LH CCW rotation pumps with B suffix input control on right side S23 12476 is for RH CW rotation pumps with A suffix input control on left side S23 12477 is for LH CCW rotation pumps with A suffix input control on right side Viewed from shaft end of pump with valve block on top 12 o clock position PARTS LIST FOR FIGURE 2 description partno quantity retaining ring use only one 089 087 2 261 2 210mm thick with yellow dot 033 71716 087 085 2 270 2 159mm thick with green dot 033 71717 085 083 2 159 2 108mm thick with white dot 033 91130 083 081 2 108 2 057mm thick with red dot 033 71718 081 079 2 057 2 007mm thick with blue dot 033 59746 retaining ring service kit thrust washer Socket head cap screw retainer piston shoe assy P24 retainer piston shoe assy P30 creep pla
67. ace If lapping is necessary check depth of pockets for valve seats after lapping Must be 085 2 16 mm minimum after lapping to provide clear ance for valve seats NOTE Do not use impact tools or o ver 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 Place valve block 1 with the six poppet valves bores up in order to press two roll pins 26 in position Roll pins to be 12 3 04 mm below surface of valve block Not required after 8 96 Install four orifice plugs 3 into valve block 1 and tighten in place Disassemble the strainer assembly 14 and reassemble per the following steps Install the orifice screw of the strainer assembly into valve block Thread elastic stop nut onto the orifice screw and torque to 23 Ibs in 2 6 Nm Install clean filter screen on strainer support and secure in place with socket head cap screw 6 32 X 1 4 Ig Torque 6 32 screw to 13 Ibs in 1 47 Nm Place valve block with poppet valve bores facing up Position gasket 29 on valve block Lubricate bores with clean hydraulic fluid Place springs 33 1 43 36 32 Ig into outer most bores at each end of the valve block Place sequence poppet 30 over these springs Position seats 27 small shoul der side first over poppets Place springs 35 1 09 27 68 mm lg into bores next to the sequence poppet valves
68. and record replenishing and servo pressure Servo pressure minus replenish pressure 30 24 series 160 to 220 psi 11 to 15 bar Replenish pressure minus case pressure Std 30 24 series 180 to 220 psi 12 4 to 15 2 bar S version 330 to 370 psi 23 26 bar If pressures are incorrect remove replenishing relief valve pilot and increase or decrease pressure as required One full turn on adjusting screw will cause pressure to change approximately 25 psi 1 7 bar Re torque locknut to 20 25 2 3 2 8 Nm Replenish pressure may be set to customer requirement not to e xceed 450 psi 31 bar NOTE There is no servo relief valve adjustment Increasing or decreasing replenishing pressure will cause both servo and replenishing pressure to change by the same amount Set the pump to compensate at 5000 psi 345 bar record replenishing and ser vo pressures Servo pressure minus replenish pressure 24 series 360 to 420 psi 24 8 to 30 bar 30 series 472 to 532 psi 32 5 to 37 bar Replenish pressure minus case pressure Std 24 series 180 to 220 psi 12 4 15 2 bar 30 series 200 to 240 psi 14 to 17 bar S version 330 to 370 psi 23 26 bar Set pump to compensate at minim um psi Servo pressures should return to the values of the previous step NOTE After completing last step proceed with pump control test refer to control service manual 51 030 Continue with the next steps after controls testing Adjust p
69. ator and stroke rotary servo input shaft from full to full position on each side of center Indicator should remain on or very near zero position 0 If compensator functions normally return compensator adjusting screw to its original position and proceed with next step Caution Do not over tighten cap screw Cycle pump at 10 second inter vals full volume above center to full volume below Center as follows 10 minutes at 1000 psi 69 bar 10 minutes at 2500 psi 172 bar 10 minutes at 5000 psi 345 bar Pumps with screw adjustment controls do not need to be cycled Adjust system pressure to 5000 psi 345 bar and set pump displacement f or full volume Check and record system flow and case drain flow above and below center Minimum system flow 24 series 160 606 30 series 220 69 385 Lpm Maximum case drain flow 24 series 12 gpm 45 4 Lpm 30 series 13 gpm 49 Lpm Set pump to compensate at 5000 psi 345 bar Servo pressure should be at least 600 psi 34 5 bar Check and record internal vane pump flow Model P P xxxx xxx X XX XX _ 0 1 2 3 4 5 6 Vane pump disp in rev 281 161 105 356 4 84 542 6 10 cc rev 461 264 172 583 79 3 88 8 100 0 Min flow at 1800 rpm gpm 213 118 7 4 270 370 415 468 Lpm 80 6 44 7 28 0 102 2 140 157 1 177 3 www comoso com BASIC PUMP TEST continued ALTERNATE TEST PROCEDURE GENERAL REQUIREMENTS 38 TEST PROCEDURE Set pump to compensate at minimum psi Check
70. b ber boot the face of the stator and the face of the carbon ring Without touching the face of the carbon seat slip the assembled spring and rubber boot onto the shaft until the spring retainer bottoms out Align the seal retainer and mounting flange bolt holes and push this assemb ly down with the seal stator face against the carbon face until the seal retainer is in the mounting flange pilot taking care to keep the parts as even as possible Secure Do not use impact tool with 4 screws and torque to required specification Allow the unit to sit for a minimum of one hour before running to allow time for the seal friction ring to adhere to the shaft Y SEAL A RETAINER ogy tt MI lt FIGURE 7 B mounting position shown 22 www comoso com ASSEMBLY PROCEDURE PARTS LIST FOR FIGURE 7 item description parno quantity segura 1 0 keyed shaftassy 82315475 mtued Cross 1 2 10 11 12 13 14 15 Te 1 _ 17 Notused OPTIONAL CONTROLS See page 64 Also see catalog S1 2AM 7501 A COUNTERBALANCE PLATE See figure 7 Place the two spacers 10 on the screws 11 and install through the ASSEMBLY balance plate 9 Align screws with the threaded holes in balance stem and tighten Torque to 70 Ibs in 6 6 Nm SERVO PLATE ASSEMBLY Replace servo plate that was removed refer to servo assembly page17 to servo stem CONTROL COVER ASSEMBLY Install gaskets
71. conds intervals full volume above center to full volume below Center as follows 10 minutes at 1000 psi 69 bar 10 minutes at 2500 psi 172 bar 10 minutes at 5000 psi 345 bar Adjust system pressure to 5000 psi 345 bar and set pump displacement f or full volume Check and record system flow and case drain flow above and below center Pumps with screw adjustment controls do not need to be cycled Minimum system flow 24 series 160 606 30 series 220 69 gpm 385 Lpm Maximum case drain flow 24 series 12 gpm 45 4 Lpm 30 series 13 49 Install special adjusting screw over modulating pin in valve block Center pump adjust special adjusting screw to reach 600 psi 41 4 bar ser vo pressure Read case drain flow as internal vane pump flow See chart first basic pump test Please refer to control service manual No S1 AM030 for control information www comoso com NOMENCLATURE For ISO circuits Figures 14 8 15 FLUID CONNECTIONS 40 FLUID CONNECTION item Q O N A 10 11 12 specification A amp B system SAE code 62 split flange AG1 BG1 A B system gage straight thread o ring seal AG2 BG2 A B system gage straight thread o ring seal C aux pump inlet servo amp repl SAE code 61 split flange D1 D2 case drains straight thread o ring seal D3 shuttle drain DG case gage straight thread o ring seal DG2 case filling for vertical mounted units
72. ds in excess of the recommended limit If the pump does not operate properly check the troubleshooting chart before attempting to over haul the unit Overhauling may be accomplished by referring to the disassembly rework limits of wear parts and assembly procedures Read and understand the instruction manual Identify components and their function Visually inspect components and lines for possible damage Check reservoir for cleanliness and drain and clean as required Check fluid level and fill as required with filtered fluid at least as clean as that recom mended Fill pump case with clean oil prior to starting Check alignment of drive eCheck oil cooler and activate it if included in circuit Reduce pressure settings of relief valve or compensator Make sure accurate pressure readings can be made at appropriate places elf solenoids are included in system check for actuation Start pump drive first by jogging prime mover Make sure pump and motor fill properly Caution Ensure that the servo replenish pump primes at startup This is important on a newly installed application or one that allows the servo replenish pump to lose its prime during shutdown Failure to adequately prime can damage the main pump or the servo replenish pump Bleed system of air Re check fluid level Cycle unloaded machine at low pressure and observe actuation at low speed if possible Increase pressure settings gradually in steps Chec
73. e NOTE If metallic thickness gage is used caution should be exercised not to scratch shoe face There are five different retaining rings available for this tolerance Each retaining ring is marked 0 081 0 079 2 03 1 98 mm thick blue dot 0 083 0 081 2 08 2 05 mm thick red dot 0 085 0 083 2 159 2 108 mm thick white dot 0 087 0 085 2 18 2 16 mm thick green dot and 0 089 0 087 2 4 2 21 mm thick yellow dot The piston and shoe assembly must be free to rotate 360 by hand See figure 3 Install two elbow fittings 3 into the threaded holes in the cr adle NOTE Check the feed tubes 4 and override tubes 2 by fitting them into the correct port block holes before assembling to the stroking assembly 5 They must be a snug push fit as they rely on a metal to metal seal to contain system pressure If they fit loose or are damaged they must be replaced Install pressure feed tubes 4 to elbow fittings 3 Tighten the connectors until snug Position the mounting flange 7 with the large open end f acing up and install two dowel pins 6 in the cradle mounting surface and one 3 8 9 5mm diameter dowel pin 10 in the outer edge of the flange Install the rocker cam and cradle assembly 5 over the dowel pins 6 in the mounting flange NOTE Pressure feed tubes to be on the same side of mounting flange center line as the 3 8 9 5 mm diameter dowel pin 10 With cam and cradle installed tilt mounting flange o
74. e 10 A special tool T4 refer assembly tools is required to press shaft seal 13 into SAE B adapter Place adapter on a clean surface with pilot facing up Use seal tool to drive seal into adapter Make certain that the white lip of seal numbered side is toward inside of the adapter Apply a light film of grease on o ring 21 install on plug 20 and thread into adapter gage ports and tighten Apply a light film of grease in sealing groove on adapter mounting face and on port block face Place tetraseals 5 in grooves in adapter and o ring 4 in groove in port block face Apply a light film of oil or grease on o ring 3 and place around pilot dia of adapter Engage pilot of adapter into bore of port block Align holes and secure with screws 7 Torque to 49 Ibs ft 66 4 Nm Install coupling 14 thru vane cartridge 2 and into auxiliary drive shaft 2 fig 4 or 4 1 See figure 11 Insert seat 2 8 into cap 2 3 and seat in bottom of bore Install small end first of piston 2 6 into b lock 2 7 Install small end first of block 2 7 into bore and against seat Install spacer 2 5 and secure in place with set scre w 2 4 Install spring 2 11 onto cone 2 9 Install spring 2 10 over spring 2 11 Install o ring 2 14 on piston 2 13 insert small end into springs and insert into cap 2 3 and seat 2 8 Install plug 2 15 screw 2 17 and nut 2 16 Set per requirement and cover with acorn nut 2 18 I
75. g plug ring servovalve use w 7F or 7G controls o ring servovalve use w 7F or 7G controls pin servovalve use w 7F or 7G controls 58 hex hd cap screw 61 orifice 56 0 0465 1 18mm Not required after 8 96 N 10 11 12 13 14 16 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 7 39 41 42 43 T 45 46 47 48 50 3 54 56 quantity 1 valve block 0083 97335 2 checkvalveassemy S1340266 2 3 or ficeplig_____ 03391249 4 4 Lomg 691 2093 2 5 03370508 1 6 soc hd screw_5 16 24 x 1 g 312 13160 1 7 hexjamnut5 16 24 3354300 1 8 housing guide 03370545 1 9 691 0040 1 10 sealpiston 936206 1 AG 1 12 03291798 1 EE _ 14 servo strainerassembly 5354401 1 15 manfod 033 54389 _ 1 manifold servovalve use w 7F 7G controls 033 54446 16 sping 2259208 1 19 1 69100900 3 20 pug 4885541 3 22 orinn 1 691 00941 10 29 pug 22 48835001 9 24 spool servovalve use w 7F 7G controls 033 54445 25 48835249 2 126 32512420 2 EE 11201 28 replenisn amp servoseat 033 0500 3 29 vaveblockgasxet 088911951 1 30 sequence poppet_________________ 033 723 8 2 31 dual amp replenishpoppet
76. in U S A 8 03 HP Denison Hydraulics Inc 14249 Industrial Parkway Marysville OH 43040 USA 937 644 3915 937 642 3738 E mail denison denisonhydraulics com Call toll free 800 551 5956 in North America or visit www denisonhydraulics com to locate a Denison representative nearest you North America Canada Denison Hydraulics Canada Inc 2880 Brighton Road Unit 1 Oakville ON L6H 553 Canada Tel 1 905 829 5800 Fax 1 905 829 5805 Latin America Mexico Central America South America Caribbean countries Denison Hydraulics Inc 7850 NW 146 Street Suite 512 Miami Lakes FL 33016 USA Tel 1 305 362 2246 Fax 1 305 362 6220 Sales 8 Service Locations Worldwide Asia Pacific Europe Australia Denison Hydraulics PTY 41 43 St Hilliers Road 192 Auburn N S W 2144 Australia Tel 61 2 9646 5200 Fax 61 2 9643 1305 Hong Kong Denison Hydraulics Ltd Unit 6A 33 F Cable TV Tower 9 Hoi Shing Road Tsuen Wan NT Hong Kong Tel 852 2498 8381 Fax 852 2499 1522 Japan Denison Japan Inc 4 2 1 Tsujido Shinmachi Fujisawa 251 0042 Japan Tel 81 466 35 3050 Fax 81 466 35 2019 People Republic of China Shanghai Denison Hydraulics Engineering Ltd Room 8018 No 601 Zhang Yang Road Pudong New Area Shanghai 200120 P R China Tel 86 21 58205042 34 Fax 86 21 58205014 Singapore Denison Hydraulics PTE LTD Blk 4012
77. ingguide 03370545 1 9 Jos 099 0097 T roller PSOP S amp 24 w contro _______ 230 82170 35 dual relief spring pilotreplen valve 24 305 52312813 pilotreplen valve P24 30P w 9A control 523 12814 8 2 o ring 48 o ring 671 00014 button hd screw 10 24 x 3 4 Ig 353 25078 i Ig Not required after 8 96 www comoso com ASSEMBLY PROCEDURE VALVE BLOCK ASSEMBLY Figure 12 STRAINER continued REPLENISHING PILOT VALVE CHECK COMPENSATOR 2997 VALVES DUAL RELIEF POPPET POPPET Assembly No S23 12742 P24P S23 12794 P30P S23 12770 P24S S23 12795 P30S S23 12796 P24 30P w 9A control FIGURE 12 32 www comoso com VALVE BLOCK ASSEMBLY FOR SERVO VALVE MOUNTING Figure 13 33 ASSEMBLY PROCEDURE 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 If lapping is necessary check depth of pockets for valve seats after lapping Must be 085 2 16 mm minimum after lapping to provide clearance for valve seats 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 Place valve block 1 with
78. ition the cradle 18 on a clean surface with the large flat side down Lightly oil curved surface of cradle Position rocker cam 21 on the cradle aligning match marks made during disassembly Place o ring 23c on vane spacer 23d and insert in the vane seal 23b Select spacer 23e such that when installed in cam ear slot there is 0000 0015 000 038 mm total clearance between spacer and slot face There are three different spacers available for this tolerance Each spacer is marked 0 2500 0 2495 6 35 6 337 mm color blue 0 2515 0 2510 6 39 6 36 mm color yellow 0 2530 0 2525 6 43 6 41 mm color green Install assembled vane seal cartridge in slotted boss on side of rocker cam as indicated Use a soft mallet and lightly tap assembly in position after rocker cam is positioned in rocker cam Install socket head cap screw 3 into cam ear and through vane assembly Torque to 30 Ibs ft 40 7 Nm Install the four nylon holddown vanes 22 in the slots on each side of the v ane seal cartridges 23 Position both control chambers 14 on a clean surface with seal grooves facing up Insert one steel ball 16 in each of the counterbored holes at the end of each of the seal grooves Coin ball in seat Install seals 17 in grooves of the control chambers NOTE The tapered side of the seals must be pushed into the grooves and the ends must cover the steel balls Install the assembled control chambers 14 over the
79. k for leaks in all lines especially pump and motor inlet lines Make correct pressure adjustments Gradually increase speed Be alert for trouble as indicated by changes in sounds sys tem shocks and air in fluid Equipment is operational WWW comoso com TROUBLESHOOTING TROUBLE SHOOTING 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 the problems by studying their effects effect of trouble fault which needs remedy noisy pump air in fluid 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 fluid too cold pump or motor fluid too viscous rotating group fluid too heavy shaft speed too high suction line too small suction line collapsed suction strainer too small or too fine suction strainer too dirty operating altitude too high boost or replenishment pressure too low replenishment flow too small for dynamic conditions misaligned shaft faulty installation distortion in mounting axial interference faulty coupling excessive overhung loads mechanical fault pist
80. l Emilia Bologna Italy Tel 39 051 6501611 Fax 39 051 736221 Spain Denison Hydraulics S A Gomis 1 08023 Barcelona Spain Tel 34 93 253 1990 Fax 34 93 211 6507 Sweden Denison Hydraulics Svenska AB Sporregatan 13 213 77 Malm Sweden Tel 46 40 600 13 00 Fax 46 40 600 13 50 Others Other European Middle East African countries Denison Hydraulics S A ATTN Export Office 14 route du bois blanc BP 538 18105 Vierzon France Tel 33 2 48 53 01 20 Fax 33 2 48 53 01 46 For more information please contact http www denisonhydraulics com Copyright O 2002 Denison Hydraulics Inc All rights reserved 4 30 02 www comoso com
81. l blow off re check pump hold down rotating group drain pressure heating of fluid excessive pump re check case drain flow and repair as required or motor leak fluid too thin age improper assembly port timing 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 for fluid needs heat exchanger water turned off or too little flow water too hot fan clogged or restricted efficiency reduced by mud or scale deposits intermittent hydraulic fluid flow reservoir too little fluid entrained air in fluid improper baffles insulating air blanket that prevents heat rejection heat pickup from adjacent equipment 9 www comoso com ASSEMBLY DISASSEMBLY TOOLS T1 No longer used T2 Barrel H D adjustment tool 228 6 9 00 1 00 25 4 9 16 36 5 50 139 7 50 12 7 20 6 57 15 41 41 14 1 62 n 2 25 DIA 5 DIA 31 75 1 4 12 2 7 87 31 D A HARDENED 1 00 DIA x 6 25 DEEP MIN STL RC58 62 25 4 158 75 5 50 139 7 T2 Material cold roll steel T3 Replenishing and servo pump removal tool remm TN IN 20 50 8mm DR 368 DIA x 1 DP 7 16 14 7 16 14 TAP THRU TAP x 1 2 DP DESCRIPTION PART NO 6 152 4mm 3 Jaw Gear Puller 2 x 486 Graingers Co x 3 DIA 4140 Steel
82. late pins The surfaces must be absolutely free of scratches dust or dirt to prevent excessive leakage Lubricate pistons with clean system fluid through the holes in the face plate CAUTION The face plate has a black break in coating on top of bronze which is bond ed to a steel backing Lightly sand the edge of the plate to identify the bronz e coated side The bronze side should go toward the port plate PARTS LIST FOR FIGURE 6 item description part no quantity barrelfaceplateP30 033 57571 6 soc hd capscrews 35810120 2 CAUTION When installing a new mechanical shaft seal exercise care to insure that all of the parts fit together properly This is particularly important if the seal was once assembled and disassembled for some reason If the rubber boot item 4 grips the shaft and does not slide on the shaft as it is disassemb led then the spring item 7 can disengage the shell item 5 from the band item 6 so that the y do not re engage properly when reassembled Be sure the shell and the band are proper ly engaged before reassembling the seal and stays engaged during assembly NOTE Re using shaft seal is not recommended practice NOTE Lubricate seal and shaft with clean hydraulic fluid of the same type that will be used in the system www comoso com ASSEMBLY PROCEDURE SEAL ASSEMBLY See figure 7 NOTE 24 series only to replace shaft seal only Remove unit for disassembly Some units require rem
83. ll on plug 23 and tighten in place Repeat step on other end of valve block WWW comoso com VALVE BLOCK ASSEMBLY FOR SERVO VALVE MOUNTING Figure 13 continued 34 ASSEMBLY PROCEDURE Lubricate o ring 19 and install on plug 20 and tighten plug in place Lubricate o rings 22 and install on plugs 23 and tighten plug in place Lubricate o rings 4 and install on plugs 25 and tighten plug in place Lubricate o ring 19 install on plug 20 and tighten plugs in place Lubricate o rings 47 and install in underside of manifold block 15 Carefully place manifold block 15 on top of the valve cover 1 making sure the o rings are correctly seated Secure with four soc hd cap screws 41 to valve block 25 Insert spring 16 and spool 38 into manifold 15 with the spring guide and spring towards the left side of the manifold 15 when viewing from the top rear Install orifice plug 61 in manifold 15 Install temporary plug 50 in 1 4 6 35 mm tube por t Insert o ring 19 and plug 20 in alternate drain port Using a small hammer carefully tap roll pins 46 into and thr u the retainer plate 42 the pins should bottom out in hole leaving enough length sticking out for piloting into the port block Lubricate o ring 47 48 and 37 and install in the bottom of retainer plate 42 Valve is ready to install on pump www comoso com ASSEMBLY PROCEDURE VALVE BLOCK ASSEMBLY FOR PARTS LIS
84. move port block 2 and port plate 4 CAUTION The port plate may cling to the barrel face because of oil film Do not allow the port plate to fall and become damaged See figure 6 Remove the face plate 2 and face plate pins 1 from the face of the barrel assembly See figure 4 1 Loosen six screws gradually in alternating sequence CAUTION Holddown is under preload Do not remove screws completely Insert three 10 32 screws into the three 10 32 threaded holes Alternately turn in screws till the tapered retainer releases A loud crack sound should be heard when it releases See figure 7 Lock main shaft from turning See figure 4 1 Use special tool T2 slip it over auxiliary shaft 2 and engage dowels into barrel holddown nut assy 5 Loosen load but do not remove See figure 6 Remove two bolts 5 holding housing and flange together www comoso com 30 series barrel holddown continued PORT BLOCK DRIVE SHAFT ROCKER CAM AND CONTROL STROKING ASSEMBLY REWORK LIMITS OF WEAR PARTS 13 UNIT DISASSEMBLY See figure 3 Push tubes 4 out of housing slots and to ward barrel do not bend or damage them See figure 6 Lift housing 4 over tubes and barrel assembly and remove Mounting flange must be driven from the housing due to tight fit NOTE Do not damage gasket faces in this process Do not remove the retaining screws or bearing from the housing unless bearing is damaged and replacement is necessary
85. n its side and secure with tw o soc hd cap screws 9 Torque to 50 106 67 8 Nm Insert plugs 11 with o rings 8 into soc hd cap screw 9 c bores Be sure tapped hole in plug 11 is visible after installation This is used for removal Install plugs 12 with o rings 13 Install shaft assembly See figure 7 Install shaft and bearing assembly 1 either splined or keyed as speci fied by inserting shaft through bores a few light taps are required on the outer race to completely engage and seat bearing NOTE Do not tap on end of shaft but on the bearing outer race only www comoso com MOUNTING FLANGE PARTS LIST FOR FIGURE 3 CAM amp CRADLE BARREL amp item description partno quantity AUXILIARY SHAFT ASSEMBLY continued 473 15041 tube assembly P24 S13 44469 tube assembly P30 S23 12172 rocker cam amp stroking ass _rocker cam 8 stroking assy 324 24028 033 57475 691 00904 Return the mounting flange to an upright position and tilt the rocker cam to either extreme attitude on the cradle Position the barrel assembly 1 directly over the pistons Starting with the uppermost piston guide them one at time into the barrel bores NOTE Support the barrel on the main shaft b ut tilted slightly so as not to allow the barrel to drop and fully engage the barrel and shaft splines Now the holddown assem BARREL AND AUXILIARY bly can be installed without any load against it DRIVE SHAFT
86. nliness can usually be accomplished by the effective use of 10 micron filters Better cleanliness levels will significantly extend the life of the components As contaminant generation may vary with each application each must be analyzed to determine proper filtration to maintain the required cleanliness level COMPARISON OF SOLID CONTAMINATION CLASSIFICATION SYSTEM NATIONAL AERONAUTICS STANDARD NAS 1638 class 00 0 1 2 3 4 5 6 7 8 9 10 11 12 5 15um 125 250 500 1000 2000 4000 8000 16000 32000 64000 128000 256000 512000 1024000 particle 15 25um 22 44 89 178 356 712 1425 2850 5700 11400 22800 45600 91200 182400 size 25 50um 4 8 16 32 63 126 253 506 1012 2025 4050 8100 16200 32400 range 50 100um 1 2 3 6 11 22 45 90 180 360 720 1440 2880 5760 gt 100um 0 0 1 1 2 4 8 16 32 64 128 256 512 1024 maximum gt 5um 152 304 609 1217 2432 4864 9731 19462 38924 77849 155698 311396 622792 1245584 particles 15um 27 54 109 217 432 864 1731 3462 6924 13849 27698 55396 110792 221584 ISO DIS 4406 SAE J1165 iso solid contaminant code 8 5 9 6 10 7 11 8 12 9 13 10 14 11 15 12 16 13 17 14 18 15 19 16 20 17 21 18 22 19 maximum 5um 250 500 1000 2000 4000 8000 16000 32000 64000 130000 250000 500000 1000000 2000000 40
87. nsert plug 2 19 into hole on spring end of cap Insert orifice plug 2 1 in center hole in cap Grease and install o rings 2 2 See figure 11 Lube spool 3 and insert it into valve body 1 When the spool is fully engaged move the spool back and forth a few times to check for smooth operation Spool must move freely in body bore Install spring stop 4 into one end of valve body 1 Make sure it is seated properly Insert spring 8 into valve body 1 over the spool 3 Install plug 12 and o ring 15 into the valve body 1 Repeat step on the other end of valve body Lube o ring 9 and place over the sleeve 5 and install into bore of valve body 1 Be careful not to jam sleeve in bore Insert piston 6 into sleeve 5 and place spring 7 into piston 6 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 soc hd screws 14 and one drilled head screw which comes with the pilot valve sub assembly Make sure that the screw that comes with the valve cap sub assembly is positioned on end closest to acorn nut Torque to 50 Ibs ft 68 Nm Run lead wire which comes with valve cap sub assembly through holes in special screw and acorn nut Twist ends together www comoso com shuttle valve assembly continued 29 ASSEMBLY PROCEDURE 2 18 2 16 5 247 943 0 A A nc
88. nt ed servo plate on right hand side or B on the left hand side Thread two size 10 24 socket head cap screws 9 thru the servo stem and into the rocker cam 21 Torque to 70 Ibs in 7 9 Nm WWW comoso com ROCKER CAM ASSEMBLY continued PISTON AND SHOE ASSEMBLY MOUNTING FLANGE CAM amp CRADLE BARREL amp AUXILIARY SHAFT ASSEMBLY FIGURE 3 18 1 P24 Shown Tapped hole this side ASSEMBLY PROCEDURE Install servo plate 10 to stem 6 with two 10 24 button head screws 8 Torque to 30 Ibs in 3 4 Nm Install two set screws 25 in servo plate Torque to 25 Ibs in 2 8 Nm NOTE The balance plate cannot be assembled to the rocker cam until after the housing assembly installation has been completed See figure 7 Install creep plate 5 over center post on rocker 21 Insert piston and shoes into retainer and install entire assemb ly 4 against creep plate Install thrust washer 2 over center post of cam and against shoe retainer Grooved side of washer must face shoe retainer Install the thickest retaining ring 1 that will fit in the groove on the rocker cam center post which will allow a maximum clearance of 0 002 0 005 0 05 0 13 mm between the creep plate and shoe faces To check this clearance grasp one piston and lift until tight against shoe retainer Insert thickness gage If this clearance is not correct select the appropriate retaining ring and repeat the checking procedur
89. on and shoe looseness or failure in pump bearing failure incorrect port plate selection or index eroded or worn parts in the displacement control erosion on barrel air in fluid see above ports and port cavitation see above plate high wear in excessive loads reduce pressure settings pump amp motor reduce speed contaminant improper filter maintenance particles in fluid 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 temperatures range breakdown of fluid with time temperature shear ing effects incorrect additives in new fluid destruction of additive effectiveness with chemi cal aging improper repair incorrect parts incorrect procedures dimensions finishes unwanted water condensation in fluid faulty breather strainer heat exchanger leakage faulty clean up practice water in make up fluid www comoso com TROUBLESHOOTING TROUBLESHOOTING effect of trouble fault which needs remedy continued cogging load worn relief valve needed repairs sator check valves servo pressure increase pressure and check pressure drop too low to through servo filter maintain firm control excessive de improve decompression control compression energy rates excessive line reduce line size or lengths capacitance eliminate hose line volume line stretch accumulator effects barre
90. oving an adapter housing and external pump Follow steps removing the internal auxiliary pump and seal plate see figure 10 Remove retaining ring 8 figure 4 Remove shaft seal Follow seal assembly in reverse order Assemble new shaft seal per instructions below After seal is replaced re install retaining ring 8 figure 4 and reassemble auxiliary pump and unit per assembly instructions CAUTION Failure to follow these instructions may result in pump failure SEAL ASSEMBLY Procedure for installation of Mechanical Shaft Seals Use only clean hydraulic fluid from the test stand or system to lubr icate the seal The fluid must be compatible with the type of seals being installed Ensure that your hands are clean at all times when installing seals Install the shaft into the unit per procedure Assure that the seal faces of the stator and carbon ring remain clean throughout the installation These parts have highly polished finishes which must be maintained to seal properly Lubricate the seal ring on the outside of the seal stator cer amic and install into seal retainer Inspect the back of the retainer to assure that the seal ring and stator are installed completely and squarely into the retainer and the stator is not tipped Care must be taken to assure that the stator is not damaged Avoid any impact on this piece Install o rings into grooves on the seal retainer as required Lubricate the shaft in the seal area the ID of the Ru
91. rque to 30 Ibs ft 40 8 Nm use item 12 for mounting fig 12 G port outlet position 2a FIGURE 10 PARTS LIST FOR FIGURE 10 description cartridge assembly CW 2 81 46 1 cc rev cartridge assembly CCW 2 81 in rev 46 1 cc rev cartridge assembly CW 1 64 in rev 26 9 cc rev S24 11789 cartridge assembly CCW 1 64 in rev 26 9 cc rev S24 51206 cartridge assembly CW 1 05 in rev 17 2 cc rev S24 11697 item E E cartridge assembly CCW 1 05 in rev 17 2 824 117 8 cartridge assembly CW 3 56 58 3 524405342 BEE cartridge assembly CCW 4 84 in rev 79 3 cc rev cartridge assembly CW 5 42 in rev 88 8 cc rev carriage Sz41812 6 endcovrsid 03391566 1 emeowerwsaE1or2 B os991605 emeowerwiSAEA2L2 08596651 7 screw cap 3582640 8 8 omg lees 1 _ plug sta 1 2 hex hd capsorew 364069 8 couping 5 32 4 035735 033 57188 27 rear drive adapter pilot valve assembly shuttle valve assembly 28 ASSEMBLY PROCEDURE PARTS LIST FOR FIGURE 10 continued iem a 691 00906 o ring SAE B 671 00155 o ring SAE C 671 00159 See figur
92. straight thread o ring seal DV external drain pilot valve FA FB control pressure gage straight thread o ring seal 96 aux pump outlet servo amp to external filter description piston pump vane chambers rotary servo auxiliary pump servo pressure relief valve modulated by operating pressure replenish pressure relief valve sequence valve compensator pilot valve override pressure valve or servo pressure sequence valve replenish ring check valve external auxiliary boost pump shuttle valve term Goldcup P2430P Goldcup P24 30S H1 aux pump inlet servo amp repl from external filter str thd O ring seal H2 servo gage straight thread o ring seal K optional replenishing supply inlet straight thread o ring seal KA shuttle relief inlet KG replenishing gage straight thread o ring seal V compensator vent VA A side vent VB B side vent straight thread o ring seal in 2 0 2 0 mm 50 8 50 8 SAE 6 6 SAE 8 8 in 2 0 2 0 mm 50 8 50 8 SAE 20 20 SAE 16 SAE 6 6 SAE 4 4 SAE 4 SAE 6 6 SAE 12 12 SAE 12 12 SAE 6 6 SAE 32 32 SAE 12 SAE 6 6 SAE 4 4 Reference viewing main shaft end of pump this port is located at 5 o clock in the standard adapter cover and at 11 o clock position in the rear drive adapters www comoso com CIRCUITS Figure 14 P24 30P
93. t 44 with the tapered bore facing down over poppet Carefully position the retainer plate over seats and poppets Pressing with one hand on the valve block compress seats poppets and springs far enough to alternately thread two button head cap screws 43 in far enough to hold the retainer plate Install the other two screws and alternately tighten screws Torque to 30 Ibs in 3 39 Nm Lubricate o ring 4 and install on to seat 5 thread seat in v alve block Be careful not to damage bore in the seat Torque to 15 Ibs in 20 34 Nm Apply vaseline to shank of cone 13 and install spring 12 on cone Carefully insert cone and spring into valve block positioning point of cone into bore of seat Lubricate o ring 11 install in groove of piston 10 and insert end of piston into spring 12 Lubricate o ring 9 and install on housing guide 8 and thread into v alve block Tighten in place Thread nut 7 on socket set screw 6 and thread screw into housing guide 8 until it starts to compress spring Using a small bladed screw driver thread the pilot replenishing relief valve assembly 36 into valve block and lightly tighten in place Do not over tighten Over tightening can cause sides of slot to break no w or at next removal Lubricate o ring 4 and install on plug 25 and tighten plug in place Thread check valve 2 into valve block and lightly tighten in place Do not over tighten Lubricate o ring 22 and insta
94. t use gasket compound 3 i 6 ri 8 9 Install two port plate pins 3 in the face of the port block assembly 2 and the dowel pins 7 into mounting surface of port block Insert lifting eyes into tapped holes in each system port mounting surface Apply heavy grease to the rear of the port plate 4 and install over the port plate pins Temporarily attach port plate to port block by inserting a cord through one of the 2 50 8 mm diameter ports down through the port block port through arcuate in the port plate around web back through port block and tie ends of the cord to lifting e ye Repeat this step to the other side of the por t plate Install the port block assembly over the auxiliary shaft and position onto tubes and dowel pins while engaging pressure feed tubes CAUTION Use extreme care and slowly lower the port block carefully onto the four tubes which are precision fit in the port block Check when the block is within 1 2 12 7 mm of seating that the tubes are square in the holes and the por t plate is seated firmly against the block Lower the block until the joint is closed Install the six bolts and washers 8 amp 9 amp 1 amp 10 Do not drop the bolts in place as the threads will be damaged Torque bolts evenly Torque bolts 1 in 50 Ib 67 8 Nm increments to 450 Ibs ft 610 Nm and the tw o bolts 8 to 120 Ibs ft 163 Nm tighten ing in turn all six bolts Torque two bolts Fig 6 items
95. te servo stem orifice screw button head cap screw Socket head cap screw 10 servo plate 033 53874 11 hex head cap screw 1 2 13 306 40174 12 hex head cap screw 3 8 16 306 40035 13R right side chamber cover CW 033 71598 right side chamber cover CCW 033 71595 left side chamber cover CW 033 71597 left side chamber cover CCW 033 71593 control chamber 033 71757 dowel pin 324 22428 steel ball 201 06001 control chamber seal 606 25045 rocker cradle 033 91141 o ring 691 00905 hexagon socket plug 488 35020 rocker cam holddown vane vane seal cartridge vane seal backup plate vane seal 033 59805 1 359 13160 2 033 91653 033 71773 033 70819 353 25023 358 10120 N A 0 m n ich Er N Oj 00 AJO 13L 15 16 18 19 0 21 22 23 23a 23b 2 item E EA E S 3 WE 1 5 6 Se 9 10 11 12 ISR E EEN 1 1 15 ae Sa 19 20 21 22 23 23 29b 23 23d 033 70816 see below 033 71726 033 71714 23c o ring 691 00128 23 vane spacer 033 71727 23e spacer O 2500 2495 6 35 6 337 mm blue 033 59806 2515 2510 6 39 6 36 mm yellow ______ 033 59983 2530 2525 6 43 6 41 mm green o33 59984 override tube P30 033 57933 2 312 09032 www comoso com ROCKER CAM ASSEMBLY 17 ASSEMBLY PROCEDURE See figure 2 Pos
96. tion and anti rust anti foam and de aerating properties as described in DENISON HYDRAULICS standard HF 1 Where anti wear additive fluids are specified see DENISON HYDRAULICS standard HF 0 Max at cold start 7500 SUS 1600 Cst at low pressure low flow and if possible low speed Max at full power 750 SUS 160 Cst Optimum for max life 140 SUS 30 Cst Minimum at full power 60 SUS 10 Cst 90 V I minimum Higher values extend the range of operating temperature but may reduce the service life of the fluid Determine by the viscosity characteristics of the fluid used Because high temperatures degrade seals reduce the service life of the fluid and create hazards fluid temperatures should not exceed 180 F 82 C at the case drain Some applications require fire resistant fluids They will give good service if the system is originally designed for their use Permissible fire resistant fluids include Type DENISON HYDRAULICS Standard Water in oil invert emulsions HF 3 Water glycol solutions HF 4 Phosphate esters HF 5 Consult DENISON HYDRAULICS for design requirements and warranty limitations for service with this class of fluids See DENISON HYDRAULICS bulletin SPO AM305 for more information Fluid must be cleaned before and continuously during operation by filters that maintain a cleanliness level of NAS 1638 class 8 class 9 for 15 micron and smaller This approximately corresponds to ISO 17 14 This fluid level clea
97. to be within 0 001 0 0254 mm after lapping The maximum permissible shoe and piston axial looseness is 0 010 0 254 mm The special retaining ring service kit S23 12629 may be required to control shoe holddown clearance www comoso com CLEANING AND INSPECTION DRIVE SHAFT AND BEARING ASSEMBLY 3 SHAFT 2 SHAFT FIGURE 1 ROCKER CAM PISTONS SHOES amp RETAINER 15 ASSEMBLY PROCEDURE All parts must be inspected and be free of mater ial defects dirt scratches or any foreign material All parts must be cleaned with a suitable cleaning solvent and all holes and passages blown out with dry clean compressed air After cleaning and inspection all parts must be covered with a light film of oil and pro tected from dirt and moisture Excessive handling of internal parts should be avoided prior to assembly During assembly lapped and ground surfaces must be lubricated with clean oil and protected from nicks or surface damage See figure 1 Slide the bearing 2 over the short end of the shaft and seat against the shoulder Support only the inner race of the bearing and press on the long end of the shaft to install bearing Do not use excessive force Use extreme care passing the ring over the seal surface Install the retaining ring 3 in the groove Be sure that the ring is fully seated PARTS LIST FOR FIGURE 1 S23 12474 DRIVE SHAFT 3 ASSEMBLY SPLINED 23 12475 DRIVE SHAFT 2 ASSEMBLY KE
98. to compress spring WWW comoso com VALVE BLOCK ASSEMBLY Figure 12 continued 31 ASSEMBLY PROCEDURE Using a small bladed screw driver thread the pilot replenishing relief valve assembly 36 into valve block and lightly tighten in place Do not over tighten Over tightening can cause sides of slot to break no w or at next removal Lubricate o ring 4 and install on plug 25 and tighten plug in place Thread check valve 2 into valve block and lightly tighten in place Do not over tighten Lubricate o ring 22 and install on plug 23 and tighten in place Repeat step on other end of valve block Lubricate o ring 19 and install on plug 20 and tighten plug in place Install pin 21 Lubricate o ring 22 and install over plug 23 and tighten plug in place Lubricate o ring 4 and install on plug 25 and tighten in place Lubricate two o rings 22 and install over two plugs 25 and tighten in place Using a small hammer carefully tap roll pins 46 into and thru the retainer plate 42 the pins should bottom out in hole lea ving enough length sticking out for piloting into the port block Lubricate o ring 47 48 and 37 and install in the bottom of retainer plate 42 Valve is ready to install on pump PARTS LIST FOR FIGURE 12 iem description quantity valve block 5 8 24 w control 083 91334 6 soc hascrew S1624x T 8 31213160 1 8 hous
99. ugh the pump We recommend 20 ft 6 09 m max per second for main flow and 4 ft 1 4 m max limit per second for suction lines The case drain flow can exceed the steady state repl pump flow during transient Size the hose for 10 ft 3 05 m max per second Pressure rating of piping hose must be adequate for service duty required An undersize inlet line will prevent the pump from operating at full rated speed An undersized outlet line will create back pressure and cause heat generation and improper operation Flexible hose lines are recommended to connect the pump to system piping If rigid piping is used the workmanship must be accurate to eliminate strain on the pump port block or to the fluid connections Sharp bends in the lines must be eliminated wherever possible All system piping must be cleaned with solvent or equivalent before installing pump Make sure the entire hydraulic system is free of dirt lint scale or other foreign material Flushing with a large temporary high pressure loop filter is recommended Piping must be cleaned so that the fluid cleanliness specified below is maintained Caution Do not use galvanized pipe Galvanized coating can flake off with continued use WWW comoso com RECOMMENDED FLUIDS VISCOSITY VISCOSITY INDEX TEMPERATURE ALTERNATE FLUIDS FLUID CLEANLINESS INSTALLATION The fluid recommended for use in these pumps has a petroleum base and contains agents which provide oxidation inhibi
100. ump displacement for full volume and adjust system pressure to 5000 psi 345 bar Adjust compensator from 5000 psi 345 bar to minim um pressure in 1000 psi 69 bar intervals At each pressure stroke rotary servo input shaft to the full position on each side of center Cam indicator should remain on or very near the zero position with no oscillation System pressure should not vary from port A to port B more than 150 psi 10 3 bar and not oscillate CAUTION Do not hold pump at 5000 psi 345 bar f or longer than one minute at any time This is only an intermittent pressure rating Minimum compensator pressure should be under 500 psi 34 5 bar Increase compensator adjustment to1000 psi 70 bar and increase and decrease sys tem pressure above and below compensator setting When system pressure is above compensator setting the pump should de stroke and not oscillate When the system pressure is below the compensator setting the pump should stroke to full volume Repeat at 5000 psi 345 bar Check pump for external leaks No external leaks permitted After all tests are completed re torque main housing bolts to 350 Ibs ft 476 Nm The following test procedure may be used if the standard closed loop test stand is not available Maximum runout between pump shaft and electric motor shaft 0 003 0 076 mm total indicator reading Electric motor speed 1800 rpm Inlet temperature 120 140 F 500 580C Inlet condition main
101. ws 53 and lift the entire block assembly from the port block See figure 12 Remove plugs 20 23 and pin 21 Remove the 8 32 nut from the bottom of block 1 to remove filter assembly 14 Do not remove the check valves 2 Remove housing 8 o ring 9 piston seal 10 o ring 11 screw 6 nut 7 and acorn nut 45 as a unit Remove spring 12 and cone 13 Remove seat 5 and o ring 4 NOTE Seat is made for hex wrenching Use 1 2 six point socket with 1 4 drive Remove plug 25 and replenishing relief valve 36 Remove o rings 37 48 and 47 Remove four screws 43 and remove the retainer plate 42 Do not remove roll pins 46 unless replacements are needed Remove gasket 29 and seats 27 and 28 Remove poppets 30 31 and springs 32 33 35 and retainer 34 Inspect orifices 3 visually to insure the y are open Do not remove unless damage or clogging is apparent See figure 7 Remove the four screws 13 with nyltite washers 12 from the side cover 15 and remove the input control assembly NOTE The nyltite washers must be replaced at assembly Remove the four screws 13 with nyltite washers 12 from the side cover 14 Remove the two screws 11 and spacers 10 and remo ve the balance plate 9 See figure 6 Remove the two screws 6 and remove the balance stem 7 NOTE 24 305 units will require removing the shuttle valve assembly and external vane pump assembl
102. y and tubing Removal of External Aux Pump Shuttle Valve Mounting Adapter and Internal Aux Pump See figure 10 Remove tubing between external pump and main pump Remove two screws holding pump Remove pump from rear drive mounting pad Remove four screws holding shuttle 19 in place Remove shuttle block Remove four screws 18 attaching shuttle adapter 17 and remo ve adapter and o rings 15 amp 16 Remove six screws 7 and mounting adapter 6 coupling 14 and gask et 22 On non rear drive units Remove plug 9 and o ring 8 Remove eight screws 7 and end cover 6 two tetraseals 5 and o rings 4 and 3 Remove auxiliary pump assembly 2 www comoso com SERVO REPLENISH PUMP AND BARREL HOLDDOWN continued 24 series barrel holddown 30 series barrel holddown 12 UNIT DISASSEMBLY NOTE This is a complete vane cartridge assembly and removed in one step A puller tool T3 is recommended Remove sealing washer 1 See figure 4 Remove holddown lock retainer ring 8 Use internal snap ring pliers See figure 9 Remove four screws 1 and two screws 8 NOTE There is a preload from the barrel holddown which will lift the port block approximately 1 8 3 2mm at release Carefully lift and remove port block 2 and port plate 4 CAUTION The port plate may cling to the barrel face because of oil film Do not allow the port plate to fall and become damaged See figure 6 Remove the

Axial Piston Pump Gold Cup Series P24P/S E-mod., P30P

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