service instructions “p-1nn” single pressure...

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

PVG SERIES F1U PUMP INSTALLATIONSSingle Pressure Compensator “P-1NN”, Installation.....................................Data Sheet 47551ARear Ported Basic Pump, Installation ...........................................................Data Sheet 47952BSide Ported Basic Pump, Installation ............................................................Data Sheet 47953CThrough Shaft Basic Pump, Installation ........................................................Data Sheet 47954AGear Pump, Installation................................................................................... Data Sheet 47945Dual Pump Adapters, Installation.................................................................... Data Sheet 47958

OILG0422

Bulletin 947651

Issued: October 2009

THE OILGEAR COMPANY2300 South 51st Street

Milwaukee, Wisconsin 53219www.oilgear.com

Bulletin 947651

2 THE OILGEAR COMPANY Bulletin 947651

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.

DANGER! !

! WARNING

CAUTION

NOTE

! WARNING

NOTE

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

Safety First

© 2009 THE OILGEAR COMPANY - ALL RIGHTS RESERVED


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

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

Safety First


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

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

Safety First


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


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

Refer to 947023 Pump Service Instructions.

Swashblock guide damaged

Low input drive speed

Worn cylinder barrel and/or valve plate mating surfaces

Failed drive shaft

Worn or damaged piston shoes and/or swashblock

Worn pistons and/or piston bores

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.


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


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.


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.


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).


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


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


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


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)



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”


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 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

307, 308, 312(4), 327, 333Nitrile Seals L723987-102 AllEPR Seals L723987-103 All

Pressure Compensator SpoolAll L723987-202 F1(A) 305, 328

Pressure Compensator AdjusterViton Seals L300574HS07 All

309, 310, 318, 331, 335, 337Buna Seals L300574HS08 All

EPR Seals L300574HS09 All

Maximim Volume StopViton Seals L516319-001 All

391C, 392C, 393C, 394C, 395C, 396CNitrile Seals L516319-003 All

EPR Seals L516319-002 All

Control Seal KitViton Seals K517107-002 All

313, 314, 330(3), 331, 333, 334(2), 335, 336, 337, 338(2), 394C, 395C, 396C

Nitrile Seals K517107-005 AllEPR Seals K517107-004 All

End Cap AssemblyViton Seals L517107-310 F1(A) 303, 304, 305, 306, 307, 308, 309, 310, 312(4), 314, 315(3),

318, 321(2), 322, 325, 327, 328, 330(2), 331, 333, 334(2), 335, 337, 338(2), 344

Nitrile Seals L517107-311 F1(A)

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



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.



Figure 7. Cross Section Parts Drawing for “P-1NN” Single Pressure Compensator, Series F1U Control (517107-200 sheet 1)

OP 1

(END

CAP

FACE

)

RP 1

330

330

344

319

313

311

OP

6

PART

IAL

SECT

ION

B-

B31

430

332

930

230

1

316A

316

315

DETA

IL B33

733

1

323

336

321

338

392C

395C

391C

393C

DETA

IL A

FO

R O

PTIO

NAL

“SN”

MAX

. VO

LUM

E ST

OP

REPL

ACE

ITEM

S 32

3 &

336

WIT

H TH

ESE

PART

S

SEE

DETA

IL A

BB

AA

OIL

G04

24

396C

394C

395C

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.

OP 1

4 (E

ND C

AP FA

CE)

SEE

DETA

IL B

310 31

8

OP

4

OP

332

5

328

306

334

304

305

307

334

322

312

327

OP

2

SECT

ION

A-A

309

334

322

338

321

333

308

335



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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.

Issued: October 2009

THE OILGEAR COMPANY2300 South 51st Street

Milwaukee, Wisconsin 53219www.oilgear.com

service instructions “p-1nn” single pressure...

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