1. Safety Precautions

• Ensure the hydraulic system is completely shut down, and the pump is disconnected from the power source (motor, engine, etc.). Lock out and tag out the power supply to prevent accidental startup during service.
• Relieve all system pressure before opening any components. Slowly loosen the pressure relief valve or a fitting to release pressure gradually; do not open high-pressure lines suddenly to avoid hydraulic fluid spray.
• Wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and oil-resistant clothing, to protect against hydraulic fluid contact, moving parts, and sharp components.
• Use only genuine Denison replacement parts and recommended tools. Non-genuine parts or improper tools may cause component failure or safety hazards.
• Work in a well-ventilated area. Avoid contact with hot hydraulic fluid, as it can cause burns. Clean up any fluid spills immediately to prevent slips and falls.
• Do not modify the pump or its components without authorization. Modifications may void the warranty and compromise the pump’s performance and safety.
• After service, inspect all connections, seals, and components for proper installation before restarting the system. Test the pump under low pressure first to check for leaks or abnormalities.

2. Product Overview

2.1 Main Series and Key Specifications

2.1.1 Piston Pumps

• Gold Cup Series (P6, P7, P8, P11, P14, P24, P30): Suitable for closed and open circuit applications. Maximum working pressure ranges from 310bar (P8 Series) to 420bar (P6, P7, P11, P14 Series), with maximum displacement from 98.3ml/rev (P6 Series) to 501.5ml/rev (P30 Series). The P6W, P7W, P8W sub-series (World Cup Series) share similar pressure and displacement parameters with their standard counterparts.
• Premier Series (P080, P110, P140, P200, P260): Designed for open circuit applications with a maximum working pressure of 500bar and maximum displacement ranging from 80.3ml/rev (P080 Series) to 262.2ml/rev (P260 Series).
• PV Series (PV6, PV10, PV15, PV20, PV29): Open circuit axial piston pumps widely used in power stations and industrial equipment. Maximum working pressure is 310bar (except PV29, which is 275bar), with displacement ranging from 14.4ml/rev (PV6) to 61.9ml/rev (PV29).

2.1.2 Vane Pumps

• Single Vane Pumps (T7B, T6C, T6D, T6E Series): Maximum working pressure ranges from 190bar to 320bar, with maximum displacement from 40ml/rev to 269ml/rev. They are lightweight (7.0Kg to 43.3Kg) and suitable for industrial and mobile machinery.
• Dual Vane Pumps (T7BB, T67CB, T6CC, etc.): Dual-pump design with two independent pressure and displacement sections. Maximum pressure for both sections is 240-320bar, and maximum displacement ranges from 50-269ml/rev (P1) and 50-158ml/rev (P2).
• Triple Vane Pumps (T67DBB, T67DCB, etc.): Three-section design with maximum pressure of 240-300bar for each section and displacement ranging from 50-269ml/rev depending on the section.

2.2 Common Model Examples

• Gold Cup Series: 013-54634-0 P6D2L1C102A, 023-83712-0 P14S2R1C2A2A000A0, 023-80475-0 P30F2R1B
• World Cup Series: 021-06298-0 P6W2R1BC0000, 021-06311-0 P7W2R1BC1000
• Premier Series: 022-81875-0 P0802L1CC10M0, 022-85768-0 P140H2L1DL1000, 022-83661-0 P260H2L1DM10D0
• Vane Pumps: T7B-B10-1R00-A1M1, T6C-025-1R00-C1, T6CC-025-020-1R00-C100

3. Installation Guidelines

3.1 Mounting Requirements

• The pump can be mounted in any orientation. The mounting hub and two-bolt mounting flange comply with SAE standards. Ensure the mounting surface is clean, flat, and free of debris to prevent vibration and misalignment.
• Align the pump shaft with the driving shaft (motor/engine) accurately. Use a dial indicator to check alignment; the maximum allowable misalignment is 0.006” TIR (0.15mm). For rigid connections without a flexible coupling, ensure the mounting pad or adapter is concentric with the pump shaft to avoid bearing failure.
• The pump should not bear the load of the pipelines. Install supports for inlet and outlet lines to prevent stress on the pump ports.
• Provide sufficient space around the pump for maintenance and inspection. Keep the area clean and free of obstacles.

3.2 Shaft Connection

• Splined Shaft: The maximum allowable misalignment is 0.006” TIR (0.15mm). Angular misalignment at the male and female spline axes must be less than ±0.002” per inch radius (0.002mm per mm radius). Lubricate the coupling interface with lithium-molybdenum disulfide or similar grease. The female coupling should be hardened to 27-45 RC and comply with SAE-J 498 B (1971) Class 1 flat root side fit.
• Keyed Shaft: Use high-strength heat-treated keys. Replacement keys must be hardened to 27-34 RC, with key corners chamfered 0.03”-0.04” (0.75-1mm) at 45° to clear keyway radii.
• Side Load Limits: C-flange pumps can accept a side load of 170 lb (77 kg), and D-flange pumps can accept 215 lb (97 kg) at the center of the spline or key, with a B10 life of 10,000 hours at 1800 rpm.

3.3 Piping and Fluid Connections

• Connect inlet and outlet lines to the pump’s port block. Ensure the pipeline size matches the port size to avoid flow restrictions and pressure loss. Use clean, debris-free pipelines; flush new pipelines before connection to prevent contamination.
• Case Pressure Limits: Maximum continuous case pressure is 75 psi (5.7 bar), and maximum intermittent case pressure is 125 psi (8.6 bar). Case pressure must never exceed inlet pressure by more than 25 psi (1.7 bar).
• Case Drain Line: Ensure the drain plumbing passes above the highest point of the pump before connecting to the reservoir. If not, install a 5 psi (0.3 bar) case pressure check valve to keep the case filled with oil at all times. The case leakage line must be large enough to prevent back pressure exceeding 75 psi (5.7 bar) and should be returned to the reservoir below the oil surface.
• Install a filter in the suction line (effective cross-section 2-3 times larger than the suction pipe) to prevent debris from entering the pump.

4. Maintenance and Servicing

4.1 Maintenance Schedule

4.2 Fluid Requirements

• Use high-quality hydraulic oil that meets Denison’s specifications (ISO VG 46 or ISO VG 68 is recommended for most applications). The oil should have a high viscosity index and good anti-wear, anti-oxidation, and anti-rust properties.
• Viscosity Range: 10 to 400 cSt (at operating temperature). Avoid using oil with excessive viscosity (may cause cavitation) or too low viscosity (may reduce lubrication and increase wear).
• Fluid Cleanliness: Maintain fluid cleanliness to ISO 14/11 (NAS 8) for new installations and ISO 16/13 (NAS 10) for regular operation. Contamination is a major cause of pump failure.
• Prohibited Fluids: Do not use water-containing fluids, highly solvent-based fluids, or contaminated oil. Water can corrode internal components, while solvents can damage seals and gaskets.

4.3 Key Maintenance Procedures

4.3.1 Fluid Change

1. Shut down the system and relieve all pressure.
2. Disconnect the drain line from the reservoir and drain the old oil into a suitable container for disposal (follow local environmental regulations).
3. Flush the reservoir and pipeline with a compatible flushing fluid to remove debris and old oil residue.
4. Reconnect the drain line and refill the reservoir with the recommended hydraulic oil to the correct level.
5. Start the system and run it at low pressure for 5-10 minutes to circulate the new oil. Check for leaks and recheck the oil level.

4.3.2 Seal Replacement

1. Shut down the system, relieve pressure, and disconnect the pump from the power source and pipelines.
2. Remove the pump from the mounting bracket and disassemble the pump housing (follow the disassembly procedure in Section 5).
3. Carefully remove the old seals (use a seal removal tool to avoid damaging the pump housing or shaft).
4. Clean the seal grooves and mating surfaces with a lint-free cloth. Ensure no debris or residue remains.
5. Install new seals (apply a thin layer of hydraulic oil to the seals for lubrication during installation).
6. Reassemble the pump, reconnect it to the system, and test for leaks.

5. Disassembly and Reassembly

5.1 Preparation for Disassembly

• Shut down the system, relieve all pressure, and disconnect the pump from the power source and pipelines.
• Drain all hydraulic oil from the pump and clean the exterior of the pump to prevent debris from entering during disassembly.
• Gather the required tools: socket set, torque wrench, screwdrivers, seal removal tool, bearing puller (if needed), and a clean workbench.
• Label all components (e.g., bolts, gears, vanes) as you remove them to ensure correct reassembly. Take photos if necessary for reference.

5.2 Disassembly Procedure

1. Remove the mounting bolts and separate the pump from the mounting bracket.
2. Remove the end cover bolts and carefully separate the end cover from the pump housing. Note the position of gaskets or O-rings between the end cover and housing.
3. For vane pumps: Remove the rotor, vanes, and cam ring from the housing. Inspect the vanes for wear, cracks, or damage (replace if necessary). Check the cam ring for scoring or wear.
4. For piston pumps: Remove the cylinder block, pistons, swashplate, and valve plate. Inspect the pistons for wear or damage, and check the swashplate and valve plate for scoring or uneven wear.
5. Remove the shaft seal from the end cover (use a seal removal tool). Inspect the pump shaft for wear, scratches, or bending.
6. Remove the bearings (if applicable) using a bearing puller. Inspect the bearings for noise, wear, or damage.
7. Clean all disassembled components with a suitable cleaning solvent. Dry thoroughly with a lint-free cloth. Do not use compressed air to dry components (may force debris into small gaps).

5.3 Reassembly Procedure

1. Install new bearings (if replacing) into the pump housing and end cover. Ensure the bearings are pressed into place correctly (use a bearing press if needed).
2. Install the new shaft seal into the end cover (apply a thin layer of hydraulic oil to the seal lip for lubrication).
3. For vane pumps: Insert the cam ring into the pump housing. Install the rotor onto the shaft, then insert the vanes into the rotor slots (ensure the vanes are oriented correctly). Apply a thin layer of hydraulic oil to the vanes and cam ring.
4. For piston pumps: Install the valve plate into the pump housing. Mount the swashplate and cylinder block, then insert the pistons into the cylinder block (ensure the pistons are seated correctly).
5. Position the end cover with a new gasket or O-ring and secure it with bolts. Tighten the bolts evenly in a crisscross pattern to the recommended torque (refer to Section 7 for torque specifications).
6. Reinstall the pump onto the mounting bracket and secure it with bolts. Tighten the bolts to the recommended torque.
7. Reconnect the inlet, outlet, and case drain lines. Ensure all connections are tight and secure.

6. Troubleshooting

7. Technical Specifications and Torque Requirements

7.1 General Technical Specifications

• Maximum Operating Temperature: 80°C (176°F) (intermittent); 60°C (140°F) (continuous)
• Minimum Operating Temperature: -20°C (-4°F) (with suitable oil)
• Shaft Speed Range: 600-2800 rpm (varies by series; refer to model-specific data)
• Filtration Requirement: Minimum 10-micron filter (recommended 5-micron for critical applications)

7.2 Torque Specifications (Typical Values)

• End Cover Bolts: 25-35 N·m (18-26 ft-lb)
• Mounting Bolts: 40-50 N·m (30-37 ft-lb)
• Shaft Nut: 80-100 N·m (59-74 ft-lb)
• Pipeline Fittings: 15-25 N·m (11-18 ft-lb) (depends on fitting size)

8. Parts and Accessories

• Shaft seals, O-rings, and gaskets
• Vanes, rotors, and cam rings (vane pumps)
• Pistons, cylinder blocks, swashplates, and valve plates (piston pumps)
• Bearings and bushings
• Filter elements

9. Warranty Information

• Improper installation, operation, or maintenance
• Use of non-genuine parts or incorrect hydraulic oil
• Contamination, overheating, or excessive load
• Unauthorized modifications or repairs