1 SERVICE INSTRUCTIONS “P-1NN” SINGLE PRESSURE COMPENSATOR FOR PVG -048/-065/-075 B-FRAME PUMP F1U SERIES CONTROL Figure 1. Typical Oilgear Type “P-1NN” Single Pressure Compensator, F1U Series Control for “PVG” -048/-065/-075 B-Frame Pumps PURPOSE OF INSTRUCTIONS These instructions will simplify the installation, operation, troubleshooting and maintenance of Oilgear type “P-1NN” Single Pressure Compensa- tor, Series F1U controlled units. This material will inform you about the basic construction, principle of operation and service parts listings. Some controls may be modified for specific applications from those described in this bulletin and other changes may be made without notice. REFERENCE MATERIAL Fluid Recommendations .......................................................................................Bulletin 90000 Contamination Evaluation Guide............................................................................Bulletin 90004 Filtration Recommendations .................................................................................Bulletin 90007 Piping Information .................................................................................................Bulletin 90011 Installation of Vertically Mounted Axial Piston Units .............................................Bulletin 90014 PVG Pumps - 048/065/075 (F1U Series) Service Instructions ............................Bulletin 947023 PVG Open Loop Pumps, Sales .......................................................................... Bulletin 47019-I PVG SERIES F1U PUMP INSTALLATIONS Single Pressure Compensator “P-1NN”, Installation..................................... Data Sheet 47551A Rear Ported Basic Pump, Installation ........................................................... Data Sheet 47952B Side Ported Basic Pump, Installation ............................................................ Data Sheet 47953C Through Shaft Basic Pump, Installation ........................................................ Data Sheet 47954A Gear Pump, Installation................................................................................... Data Sheet 47945 Dual Pump Adapters, Installation.................................................................... Data Sheet 47958 OILG0422 Bulletin 947651 Issued: October 2009 THE OILGEAR COMPANY 2300 South 51st Street Milwaukee, Wisconsin 53219 www.oilgear.com Bulletin 947651
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Bulletin 947651 THE OILGEAR COMPANY 1
SERVICE INSTRUCTIONS “P-1NN” SINGLE PRESSURE COMPENSATOR
FOR PVG -048/-065/-075 B-FRAME PUMP F1U SERIES CONTROL
Figure 1. Typical Oilgear Type “P-1NN” Single Pressure Compensator, F1U Series Control for “PVG” -048/-065/-075 B-Frame Pumps
PURPOSE OF INSTRUCTIONSThese instructions will simplify the installation,operation, troubleshooting and maintenance ofOilgear type “P-1NN” Single Pressure Compensa-tor, Series F1U controlled units.
This material will inform you about the basicconstruction, principle of operation and serviceparts listings. Some controls may be modified forspecific applications from those described in thisbulletin and other changes may be made withoutnotice.
REFERENCE MATERIALFluid Recommendations .......................................................................................Bulletin 90000Contamination Evaluation Guide............................................................................Bulletin 90004Filtration Recommendations .................................................................................Bulletin 90007Piping Information .................................................................................................Bulletin 90011Installation of Vertically Mounted Axial Piston Units .............................................Bulletin 90014PVG Pumps - 048/065/075 (F1U Series) Service Instructions ............................Bulletin 947023PVG Open Loop Pumps, Sales .......................................................................... Bulletin 47019-I
Read and understand this entire instruction sheetbefore repairing or adjusting your Oilgear product.
Those who use and maintain this equipment mustbe thoroughly trained and familiar with the product.If incorrectly used or maintained, this product andits equipment can cause severe injury.
SAFETY SYMBOLSThe following signal words are used in thisinstruction sheet to identify areas of concern whereyour safety may be involved. Carefully read the textand observe any instructions provided to ensureyour safety.
THIS SIGNAL WORD INDICATES AN IMMI-NENTLY HAZARDOUS SITUATION WHICH,IF NOT AVOIDED, WILL RESULT IN DEATHOR SERIOUS INJURY.
This signal word indicates a potentiallyhazardous situation which, if not avoided,could result in death or serious injury.
This signal word indicates that a potentiallyhazardous situation exists which, if notavoided, may result in damage toequipment or minor personal injury.
While not directly relevant to the topic beingdiscussed, the NOTE is used to emphasizeinformation provided, or provide additionalinformation which may be of benefit.
This service information is designed forthe maintenance of your Oilgear product.It contains the information on the correctprocedures determined by Oilgear for thesafe manner of servicing. Always keepthis instruction sheet in a location where itis readily available for the persons whouse and maintain the product. Additionalcopies of this instruction sheet areavailable through Oilgear. Contact us at414-327-1700 or visit our website:www.oilgear.com. Please contact us if youhave any questions regarding theinformation in this instruction bulletin.
The cleanliness of working on this pumpcontrol or the hydraulic system is extremelyimportant to the safety and reliability of thepump and the system. Always make surethe fittings are clean on the outside beforeremoving them from their connections, arecapped and plugged when removed, andare placed in a clean rag or container untilthey are reinstalled.
Some service operations may requirespecial tools or equipment. If you requireinformation on these items, please contactOilgear before attempting these repairsand service operations.
Read, understand and follow the safetyguidelines, dangers and warningscontained in this instruction sheet topromote reliable operation and preventserious personal injury.
DO NOT attempt to service this machineryin an environment where safety regulationsare not established and in place.
DO NOT operate the hydraulic system if aleak is present. Serious injury may result.
Hydraulic systems operate under very highpressure. Hydraulic fluid escaping from apressurized system can penetrateunprotected body tissue. DO NOT inspectfor hydraulic leaks with bare hands or otherexposed body parts. As a minimum, wearleather gloves prior to inspecting for leaksand use cardboard or wood. If leaks arepresent, relieve pressure and allow systemto cool prior to servicing. If injured byescaping hydraulic oil, contact a physicianimmediately. Serious complications mayarise if not treated immediately. If you havequestions regarding inspecting forhydraulic leaks, please contact Oilgearprior to servicing.
Hydraulic hoses and tubing must beinspected on a daily basis for leaks, cuts,abrasions, damage and improperclearance along any mounting frame forhidden damage before the unit is put intoservice. Replace damaged hoses or hosesyou suspect are damaged before thesystem is returned to service! Hoses mustbe replaced every 2 years. Failure toproperly inspect and maintain the systemmay result in serious injury.
Hydraulic systems are hot. DO NOTTOUCH! Serious personal injury mayresult from hot oil. When you havecompleted working on the hydraulicsystem, thoroughly clean any spilled oilfrom the equipment. Do not spill anyhydraulic fluids on the ground. Clean anyhydraulic fluids from your skin as soon asyou have completed maintenance andrepairs. Dispose of used oil and systemfilters as required by law.
Use hoses, fittings and adapters with thecorrect SAE rating when replacing hosesto prevent possible serious injury. Alwaysreplace hoses, fittings and adapters withreplacements that have a proper, suitable,working pressure rating. Replacementhoses must be of the correct length andmust comply with the hose manufacturer’sand Oilgear’s installation guidelines andrecommendations.
Hydraulic hoses have the SAE ratingsmarked on the hose to assist you inselecting the correct hose. The samemanufacturer must supply any replacementhydraulic hoses and fitting assemblies. Asan example: Brand “X” hose and brand “Y”fitting will not normally be compatible. No“Twist” is allowed in the hydraulic hoses.“Twist” may result in premature hosefailure. This can cause serious injury.Please contact Oilgear for assistance whenrequired.
Hydraulic cylinders can be holding afunction in a certain position when thepump is off. An example of this is afunction being held in the lift or partial liftposition by the cylinders. If a hydraulicline is removed or the hydraulic circuits orcontrols are being worked on, gravity mayallow the function being held in position todrop. All workers and personnel mustremain clear of these areas when workingon or operating the hydraulic system.Block and secure all devices andfunctions which apply before beginningwork or operation. Failure to comply withthis can result in serious injury or death.
Any hydraulic pipe which is replaced mustconform to SAE J1065 specifications. Ifincorrect hydraulic pipe is installed, thehydraulic system may fail, causingserious injury. Damaged or leakingfittings, pipes or hoses must be replacedbefore the system is returned to service.
DO NOT heat hydraulic pipe. The carboncontent of this steel tube is such that ifheated for bending, and either water or airquenched, the pipe may lose its ductilityand thereby be subject to failure underhigh pressure conditions. Serious injurycan result. Damaged or leaking pipes mustbe replaced before the system is returnedto service. Please contact Oilgear if yourequire assistance or have questions.
All hydraulic pressure must be relievedfrom the hydraulic system prior to removingany components from the system. Torelieve the hydraulic pressure from thehydraulic system, turn off the motor andoperate the control panel with the key in theON position. Failure to comply can result inserious injury. If you have any questionsconcerning relieving the hydraulic pressurefrom the system, please contact Oilgear.
! WARNING
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Safety First
4 THE OILGEAR COMPANY Bulletin 947651
Hydraulic components can be heavy. Usecaution while lifting these components.Serious personal injury can be avoidedwith proper handling of the components.
Please contact Oilgear if you requireassistance. When performing hydraulictest procedures, use the proper hydraulicgauges. Installing an incorrect test gaugecould result in serious injury if the gaugefails. Use properly rated hydraulic hosesto allow the test gauge to be read awayfrom moving parts and functions.
Increasing hydraulic pressure beyond therecommendations may result in seriousdamage to the pump and system orserious personal injury, and may void theOilgear Warranty. If you have questionsconcerning hydraulic pressures or testingprocedures, please contact Oilgear beforeattempting the test procedures or makingadjustments.
An Oilgear pump or pump control mustnot be modified in any way withoutauthorization from Oilgear. Modificationsmay not comply with safety standards,including ANSI safety standards, and mayresult in serious personal injury. Pleasecontact Oilgear if you require assistance.
DO NOT enter under hydraulic-supportedequipment unless it is fully supported orblocked. Failure to follow this procedurecan result in serious injury or death.
Any Oilgear pump safety decals must bereplaced anytime they are damaged,missing or cannot be read clearly. Failureto have proper decals in place can resultin serious injury or death. (If you requiresafety decals, please contact Oilgear forreplacement safety decals, at no charge.)
Be sure everyone is clear of the areaaround the hydraulic system beforeoperating after servicing. Remain attentiveat all times when operating to check yourwork until you are completely sure it issafe to return to service. Failure to heedthis warning may result in seriouspersonal injury or death.
Wear the proper protective clothing whenoperating, servicing or maintaining thehydraulic system or the Oilgear pump. Wearthe correct protective gear, safety glasses,gloves and safety shoes. Serious injury canresult without proper protective gear.
Make sure to keep hands, feet and otherparts of your body clear of revolving ormoving parts. Failure to comply can causeserious injury.
DO NOT wear watches, rings or jewelrywhile working with electrical and mechani-cal equipment. These items can be hazard-ous and can cause serious and painfulinjuries if they come into contact with elec-trical wires, moving parts or hydraulicequipment.
! WARNING
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Bulletin 947651 THE OILGEAR COMPANY 5
Figure 2. ASA Diagram for “P-1NN” Control Shown with Typical Pump
Figure 3. Curve Indicating Flow Versus Pressure for “P-1NN” Type Control
A
1B
GPA
OP 1 OP 2
OP 6
OP 3 OP 4
RP1
1A
OP 14
OILG0448
FL
OW
PRESSURE Related PumpPressure
OILG0380
6 THE OILGEAR COMPANY Bulletin 947651
TROUBLESHOOTINGPROBLEM CAUSES REMEDY
Unresponsive or Unstable Control
Swashblock bearing surface and/or saddle bearings worn or damaged Refer to 947023 Pump Service Instructions.Swashblock guide damaged
Fluid is contaminatedInspect and clean if necessary. Refer to FiltrationRecommendations Bulletin 90007.
Contamination trapped between control piston and bore not allowing piston to move smoothly Inspect and clean if necessary. Replace damaged
parts.Contamination trapped between control spool and bore not allowing spool to move smoothly
Insufficient control flow Increase size of control orifice “OP 6.”
Worn or damaged pilot relief seat and/or poppetInspect and replace if necessary.
Faulty remote function circuit
Hydraulic line between remote fuction and pump port RP1 is incorrect
Change hydraulic line.
Insufficient Outlet Volume
Swashblock bearing surface and/or saddle bearings worn or damaged
Maximum volume stop adjusted incorrectly Adjust maximum volume stop CCW to increase flow.
Pressure compensator is set too close to operating pressureAdjust pressure compensator CW to increase pressure.
Control piston stuck off strokeInspect and replace if necessary.
Faulty remote function circuit
Unable to Develop Full Pressure
System requires more flow than available Check system for leaks or open functions.
Pressure compensator adjustment not set correctlyAdjust pressure compensator CW to increase pressure.
Contamination in control spool
Inspect and clean if necessary.Worn or damaged pilot relief seat and/or poppet
Control piston stuck off stroke
Faulty remote function circuit
Excessive Pressure
Swashblock bearing surface and/or saddle bearings worn or damaged Refer to 947023 Pump Service Instructions.
Swashblock guide damaged
Pressure compensator adjustment not set correctlyAdjust pressure compensator CCW to decrease pressure.
Contamination in “OP 3” or “OP 4”Inspect and clean if necessary.
Restricted passage between outlet and control spool
Contamination trapped between control piston and bore is not allowing piston to move smoothly Inspect and clean if necessary. Replace damaged
parts.Contamination trapped between control spool and bore not allowing spool to move smoothly
Faulty remote function circuit Inspect and replace if necessary.
Bulletin 947651 THE OILGEAR COMPANY 7
GENERALOperation for a typical pump is described. Sectiondiagrams are a representation of typical pumpswith “P-1NN” control.
Functionally, the swashblock (and resultantdelivery) is positioned by two opposite (acting)control pistons.
See control parts drawing for actual configurationand location of part assemblies, orifices,connections and ports.
PRINCIPLE OF OPERATION
STARTING
The bias spring positions the control andconnected pump swashblock so that the pump willdeliver maximum volume to raise pressure in thesystem.
8 THE OILGEAR COMPANY Bulletin 947651
RAISING PRESSURE - LOADING
Pump delivery (and resultant pressure) is fed backto the control through Port “OP 1.” The pressurecompensating spool (305) is held in position by apilot control valve spring (328). Flow (and resultantpressure) is transmitted through the pressurecompensating spool (305) to the bias control pistonand through orifice Port “OP 2.”
Pressure acting on either end of the pilot controlvalve is equal. The spool is balanced and held inposition by the control valve spring (328). Flow(and resultant pressure) is also transmitted throughPort “OP 3” and Port “OP 4” to the adjustablecontrol relief valve (310), which blocks further flowin the control (and pressure transmittal).
Bulletin 947651 THE OILGEAR COMPANY 9
Figure 4. Raising Pressure - Loading
OILG0366
UNLOADINGCONTROL
BIASCONTROL
CONTROL PIN
SWASHBLOCK
TO SYSTEM
OP 2 (305) OP 1
OP 14
OP 3
(328)
OP 4 (308) (307) (327) 310
OP 6
10 THE OILGEAR COMPANY Bulletin 947651
COMPENSATING PRESSURE - UNLOADING
When pressure on the relief valve poppet (307)exceeds the presetting of the relief valve screw(310): Set by turning the valve screw in or out,which sets the force of the relief valve spring (327).The relief valve poppet (307) moves off seat (308)and allows flow through the valve, and throughdrain line to pump case and case drain. Pressure isreduced on the spring end of the pressurecompensating spool (305).
Flow through “OP 2” reduces pressure on thespring end of the pressure compensating spool(305). There is still full pressure on the other end ofthe pressure compensating spool. This differentialpressure forces the pressure compensating spool(305) to shift and compress the control valve spring(328). The pressure compensating spool nowallows pump delivery (and resultant pressure) toflow to the unloading control piston. The pressurecompensating spool simultaneously drains the fluidfrom behind the bias control piston.
The control piston now moves the control pin andshifts the swashblock to a position towards neutral,where the pump delivers sufficient volume tomaintain system pressure as regulated by thecontrol relief valve (310).
HOLDING PRESSURE
If the system pressure drops below presetcompensating pressure, the relief valve poppet(307) seats and forces on the pressurecompensating spool (305) are balanced, the pilotcontrol valve spring (328) returns the spool to theoriginal position (Figure 4), swashblock positionshifts, and the pump increases delivery until therelief valve screw (310) preset pressure is reachedagain.
ORIFICE FUNCTIONS
“OP 2” Integral to spool, item 305
“OP 4” Integral to seat, item 308
“OP 14” Integral to end cap, item 304
OrificeNumber
Decreasing orifice diameter will result in: (increasing diameter
will do the opposite)“OP 1” Do not decrease to less than .125"“OP 2” Do not change“OP 3” Do not change“OP 4” Do not change“OP 6” Decreased stability“OP 14” Do not change
Bulletin 947651 THE OILGEAR COMPANY 11
Figure 5. Compensating Pressure - Unloading
OILG0367
TO SYSTEM
OP 2 (305)OP 1
OP 14
OP 3
(328)
OP 4 (308) (307) (327) (310)
UNLOADINGCONTROL
BIASCONTROL
CONTROL PIN
SWASHBLOCK
OP 6
12 THE OILGEAR COMPANY Bulletin 947651
SCREW AND PLUG TORQUES FOR “P-1NN” CONTROL
CONTROL O-RING SEALS
* Teflon Backup Ring
Item Number Head Type & Hex Size Tightening Torque
306 7/8 external 50 ft•lb (68 N•m)
308 7/16 external 200 in•lb (23 N•m)
309 1 external 80 ft•lb (108 N•m)
315 1/4 internal 30 ft•lb (41 N•m)
316 3/8 internal 65 ft•lb (88 N•m)
316A 3/8 internal 65 ft•lb (88 N•m)
319 5/32 internal 48 in•lb (5 N•m)
321 3/16 internal 120 in•lb (14 N•m)
322 7/8 external 50 ft•lb (68 N•m)
323 9/16 internal 85 ft•lb (115 N•m)
325 5/32 internal 48 in•lb (5 N•m)
344 5/32 internal 48 in•lb (5 N•m)
391C 1 1/4 external 85 ft•lb (115 N•m)
Item Number ARP 568 Uniform Size Number Shore A Durometer
313 -243 70
314 -132 70
330 -013 90
331 -014 90
333 -906 90
334 -908 90
335 -910 90
336 -912 90
337 -014 *
338 -904 90
394C -014 90
395C -912 90
396C -014 *
PVG -048/-065/-075 B-Frame Pump “P-1NN”
Bulletin 947651 THE OILGEAR COMPANY 13
PARTS LISTParts used in these assemblies are per Oilgearspecifications. Use only Oilgear parts to ensurecompatibility with assembly requirements. Whenordering replacement parts, be sure to includepump type and serial number, and bulletin numberand item number. Specify type of hydraulic fluid toensure seal and packing compatibility.
Item Description Qty301 Control Housing 1302 Control Piston 1303 Reduced Area Piston 1304 End Cap 1305 Compensator Spool 1306 End Plug, Spring End 1307 Pilot Relief Poppet 1308 Pilot Relief Seat 1309 Pilot Relief Bonnet 1310 Pilot Relief Adjusting Screw 1311 Control Pin 1312 Shim 4313 O-ring 1314 O-ring 1315 Screw 3316 Screw 1
316A Screw 2318 Jam Nut 1319 Orifice 1321 SAE #4 Plug 2322 Filter End Plug 1323 SAE #12 Plug 1325 Orifice 1327 Spring 1328 Spring 1329 Spring 1330 O-ring 3331 O-ring 1333 O-ring 1334 O-ring 2335 O-ring 1336 O-ring 1337 Backup Ring 1338 O-ring 2344 Orifice 1
391C Maximum Stop Bonnet 1392C Maximum Stop Adjusting Screw 1393C Jam Nut 1394C O-ring 1395C O-ring 1396C Backup Ring 1
PVG -048/-065/-075 B-Frame Pump “P-1NN”
14 THE OILGEAR COMPANY Bulletin 947651
PVG B P-1NN Control Service KitsReference: 517107-200 Ass’y Drwg
Document Number: 517107-SK
Revision: 0 (04-21-09)
Sheet 1 of 1
Description Kit No.Design Series Items Included (quantity is 1 unless noted)
Control Pistons / SpringAll L723987-002 F1(A) 302, 303, 329
Pressure Compensator ReliefViton Seals L723987-101 All
EPR Seals L517107-312 F1(A)Footnotes for Design Series(A) End cap must match control housing, control housing must match pump housing A1, B1, B2 end caps fit A1, B1, B2 control housings A1, B1, B2 pressure compensator spools fit A1, B1, B2 control housings A1, B1, B2 control pistons fit A1, B1, B2 control housings A1, B1, B2 control housings fit A1, B1, B2 pump housings F1 series end caps fit F1 series control housings F1 pressure compensator spools fit F1 control housings F1 control pistons fit F1 control housings F1 control housings fit F1 pump housings
PVG -048/-065/-075 B-Frame Pump “P-1NN”
Bulletin 947651 THE OILGEAR COMPANY 15
Figure 6. Exploded Parts Drawing for “P-1NN” Single Pressure Compensator, Series F1U Control (517107-200 sheet 2)
328
334
306
304
344
OP
132
9
314
303
302
330
316A
316
301
336
323
319
311
330
313
OP
6
305
OP
233
432
2
310
331
337
309
335
318
327
312
307
333
308 OP
4
338
321
325
OP
3RP 1
338
321
315
394C
392C
396C
395C
391C39
3 C
OIL
G04
23
FOR
OPT
IONA
L "S
N"M
AX. V
OLU
ME
STO
P RE
PLAC
E IT
EMS
323
& 33
6 W
ITH
THES
E PA
RTS
NO
TE
: VO
LUM
E ST
OP
IS A
DJUS
TABL
E FR
OM
FU
LL S
TRO
KE T
O N
EUTR
AL W
ITH
TWEL
VE T
URNS
(8%
PER
TUR
N).
CLO
CKW
ISE
REDU
CES
STRO
KE.
PVG -048/-065/-075 B-Frame Pump “P-1NN”
16 THE OILGEAR COMPANY Bulletin 947651
Figure 7. Cross Section Parts Drawing for “P-1NN” Single Pressure Compensator, Series F1U Control (517107-200 sheet 1)
AFTER SALES SERVICESAt Oilgear we build products to last. It is the natureof this type of machinery to require propermaintenance regardless of the care we put intomanufacturing. Oilgear has several serviceprograms in place to help you.
STAY-ON-STREAM SERVICE
By signing up for Oilgear’s Stay-On-Streamprogram, you can prepare for problems before theyhappen. Certain field tests such as fluid testing,slip testing and electronic profile recordingcomparisons can be performed by our field servicepeople or your own factory trained personnel.These tests can indicate problems before theybecome “down-time” difficulties.
SERVICE SCHOOLS
Oilgear conducts training to train your maintenancepersonnel. “General” hydraulic or electronictraining is conducted at our Milwaukee, Wisconsinplant on a regular basis. “Custom” training,specifically addressing your particular hydraulicand electro-hydraulic equipment, can be conductedat your facilities.
SPARE PARTS AVAILABILITY
Prepare for your future needs by stocking Oilgearoriginal factory parts. Having the correct parts andnecessary skills “in-plant” enables you to minimize“down-time.” Oilgear has developed parts kits tocover likely future needs. Oilgear Field ServiceTechnicians are also ready to assist you and yourmaintenance people in troubleshooting andrepairing equipment.