pvg 947675 - oilgear · 2019. 8. 30. · title: pvg_947675.fm created date: 3/18/2010 11:26:19 am

Bulletin 947675 THE OILGEAR COMPANY 1

SERVICE INSTRUCTIONS“P-1NN” SINGLE PRESSURE COMPENSATOR FOR PVG-150 PUMP, A1 SERIES CONTROL

Figure 1. Typical Oilgear Type “P-1NN” Single Pressure Compensator Control for PVG-150 Pumps

PURPOSE OF INSTRUCTIONSThese instructions will simplify the installation,operation, troubleshooting and maintenance ofO i lgear t ype “P -1NN” S ing le PressureCompensator 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 Pump - 150 Service Instructions .................................................................Bulletin 947034PVG Open Loop Pumps, Sales ..........................................................................Bulletin 47019-J

PVG-150 PUMP INSTALLATIONSSingle Pressure Compensator “P-1NN,” Installation ....................................... Data Sheet 47377Basic Pump, Installation.................................................................................. Data Sheet 47375Through Shaft Basic Pump, Installation .......................................................... Data Sheet 47376Gear Pump, Installation................................................................................... Data Sheet 47945Dual Pump 2-Bolt SAE Adapters, Installation ................................................. Data Sheet 47387Dual Pump 4-Bolt SAE Adapters, Installation ................................................. Data Sheet 47388

OILG0478

Bulletin 947675

Issued: February 2010

THE OILGEAR COMPANY2300 South 51st Street

Milwaukee, Wisconsin 53219www.oilgear.com

Bulletin 947675

2 THE OILGEAR COMPANY Bulletin 947675

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

© 2010 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

OILG0331

FL

OW

PRESSURE Related PumpPressureOILG0380


TROUBLESHOOTINGPROBLEM CAUSES REMEDY

Unresponsive or Unstable Control

Swashblock bearing surface and/or saddle bearings worn or damaged

Refer to 947034 Pump Service Instructions.

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



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



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.


PRINCIPLE OF OPERATIONOperation for a typical pump is described. Sectiondiagrams are a representation of typical pumpswith “P-1NN” control.

Functionally, the swashblock (and resultantdisplacement) is positioned by two opposite actingcontrol pistons (unloading control piston and biascontrol piston).

See control parts drawing for actual configurationand loca t ion o f par t assembl ies, or i f i ces,connections and ports.

STARTING

The bias spring (329) positions the control pistonsand connected pump swashblock so that the pumpis at maximum displacement to raise pressure inthe system.


RAISING PRESSURE - LOADING

Pump outlet pressure is ported to the controlthrough Port “OP 1” to the control spool (305) andto the bias control piston (303). Outlet pressure isalso transmitted through orifice Port “OP 2,”allowing the pressure acting on either end of thecontrol spool (305) to be equal. In this condition,the control spool (305) is held in position only bythe spring (328).

The outlet pressure through Port “OP 2” is furthertransmitted through Port “OP 3” and Port “OP 4” tothe adjustable pressure compensator relief valve.


Figure 4. Raising Pressure - Loading

TO SYSTEM

UNLOADINGCONTROL

BIASCONTROL

OP 4

OP 3OP 2

OP 14OPTIONAL

OP 1

OP 6

(328)

(305)

PRESSURECOMPENSATORRELIEF VALVE

CONTROL PIN

SWASHBLOCK(329)

(303)

OILG0474


COMPENSATING PRESSURE - UNLOADING

When pressure on the relief valve poppet (307)exceeds the presetting of the relief valve spring(327), the relief valve poppet (307) moves off seat(308) and allows flow through the relief valve todrain. Pressure on the spring end of the controlspool (305) is decreased, causing a pressuredifferential across the spool (305). The pressuredifferential forces the control spool (305) to shiftand compress the spring (328). Outlet pressure isthen ported to the unloading control piston (302),and fluid behind the bias control piston (303) isported to drain. Pump displacement will decreaseto maintain system pressure as set by the reliefvalve adjuster (310).

HOLDING PRESSURE

If the system pressure drops below the presetcompensating pressure, the relief valve poppet(307) seats and closes the path to drain. Pressureon either side of the control spool (305) willbecome equal and the spring (328) will shift thespool (305) to the original position (Figure 4).Fluid from the unloading control piston (302) isthen ported to drain and outlet pressure is portedto the b ias con t ro l p i s ton (303 ) . Pumpdisplacement will increase until the relief valvesetting is reached again.

ORIFICE FUNCTIONS

“OP 1” Orifice not used (standard)

“OP 2” Integral to spool, item 305

“OP 4” Integral to seat, item 308

“OP 6” .089 orifice

“OP 14” Orifice not used (standard)

OrificeNumber

Decreasing orifice diameter will result in: (increasing diameter

will do the opposite)

“OP 1” Decreased “off stroke” time, do not decrease to less than .125"“OP 2” Fixed, not adjustable“OP 3” Do not change“OP 4” Fixed, not adjustable“OP 6” Decreased stability

“OP 14” Decreased “on stroke” time, do not decrease to less than .081"


Figure 5. Compensating Pressure - Unloading

TO SYSTEM

UNLOADINGCONTROL

BIASCONTROL

OP 4(308)

OP 3OP 2

OP 14OPTIONAL

OP 1

OP 6

(328)

(305)(327)

(310)

(307)

CONTROL PIN

SWASHBLOCK

(303)(302)

OILG0475


SCREW AND PLUG TORQUES FOR PVG-150 “P-1NN” CONTROL

CONTROL O-RING SEALS

* Teflon Backup Ring** 90 durometer viton seals used

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)

315A 3/8 internal 100 ft•lb (136 N•m)

315B 3/8 internal 100 ft•lb (136 N•m)

316 3/8 internal 100 ft•lb (136 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 1 1/4 external 120 ft•lb (163 N•m)



720 1 1/4 external 120 ft•lb (163 N•m)

Item Number ARP 568 Uniform Size Number Shore A Durometer

Viton HNBR EPR

314 -140 70 75 80

330 -013 90 90 80

331 -014 90 90 80

333 -906 90 90 80

334 -908 90 90 80

335 -910 90 90 80

336 -912 90 90 80

337 -014 * * *

338 -904 90 90** 80

345 -903 90 90** 80

399 -014 * * *

1014 -014 90 90 80

1912 -912 90 90 80


PARTS LIST FOR PVG-150 “P-1NN” CONTROLParts 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 Unloading Control Piston 1303 Bias Control Piston 1304 End Cap 1305 Control Spool 1306 End Plug, Spring End 1307 Relief Valve Poppet 1308 Seat 1309 Pilot Relief Bonnet 1310 Relief Valve Adjuster 1312 Shim 4314 O-ring 1

315A Screw 2315B Screw 1316 Screw 4318 Jam Nut 1319 Orifice 1321 SAE #4 Plug 2322 Filter End Plug 1323 Maximum Volume Plug 1325 Orifice 1327 Relief Valve Spring 1328 Spring 1329 Bias 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 2340 Permanent Plug 1342 SAE #3 Plug 2345 O-ring 2348 Pin 2399 Backup Ring 1718 Maximum Stop Adjusting Screw 1719 Jam Nut 1720 Maximum Stop Bonnet 11014 O-ring 11912 O-ring 1


PVG-150 P-1NN Control Service KitsReference: 520167-101 Ass’y Drwg

Document Number: 520167-SK1

Revision: 0

Sheet 1 of 1

Description Kit No.Design Series Items Included (quantity is 1 unless noted)

Control Pistons & SpringAll K318946-001 A1 302, 303, 329

Pressure Compensator ReliefViton Seals L723987-101

A1 307, 308, 312(4), 327, 333HNBR Seals L723987-104EPR Seals L723987-103

Pressure Compensator SpoolAll L724407-002 A1 305, 328

Pressure Compensator AdjusterViton Seals L300574HS04

A1 309, 310, 318, 331, 335, 337HNBR Seals L300574HS10

EPR Seals L300574HS06

Adjustable Maximum Volume StopViton Seals L516319-006

A1 399, 718, 719, 720, 1014, 1912HNBR Seals L516319-007

EPR Seals L516319-008

Control Seal KitViton Seals K516183-008

A1314, 330(3), 331, 333, 334(2), 335, 336, 337, 338(2), 345(2), 399, 1014, 1912

HNBR Seals K516183-009EPR Seals K516183-010

End Cap AssemblyViton Seals K520143-101

A1303, 304, 305, 306, 307, 308, 309, 310, 312(4), 314, 315A(2), 315B, 318, 321(2), 322, 325, 327, 328, 330(3), 331, 333, 334(2), 335, 337, 338(2), 340

HNBR Seals K520143-102

EPR Seals K520143-103


Figure 6. Exploded Parts Drawing for PVG-150 “P-1NN” Single Pressure Compensator Control (520167-101 sheet 1)

RP1

OP1

4(E

ND C

AP F

ACE)

306

334

328

321

338

321

3383253

15B

315A

304

340

308

333

307

312

327

310

309

335

318

305

322

334

314

303

329

302

348

OP1

(END

CAP

FAC

E)

331

337

ADJU

STAB

LE M

AXIM

UM V

OLU

ME

STO

P 719

718

399

720

1912

1014

FIXE

D M

AXIM

UMVO

LUM

E ST

OP

342

345

323

336

301

316

342

345

319

330

OP6

OP2

OP3 O

P4

OIL

G04

77


Figure 7. Cross Section Parts Drawing for PVG-150 “P-1NN” Single Pressure Compensator Control (520167-101 sheet 2)

FIXE

D M

AXIM

UMVO

LUM

E ST

OP

ADJU

STAB

LE M

AXIM

UM V

OLU

ME

STO

P

342

345

319

OP6

SECT

ION

B-B

323

336

314

303

302

329

301

316

SECT

ION

A-A

SEE

321

338

308

333

325

306

334

328

322

334

305

309

335

310

312

327

318

307

304

RP

1

315B321

338

315A

DETA

IL E

331

337

SEE

DETA

IL A

720

1912

718

719

DETA

IL A10

1439

9

DETA

IL E

OIL

G04

76

BB

A A

OP2

OP3

OP4


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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 intomanufactur ing. 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: February 2010

THE OILGEAR COMPANY2300 South 51st Street

Milwaukee, Wisconsin 53219www.oilgear.com

pvg 947675 - oilgear · 2019. 8. 30. · title: pvg_947675.fm created date: 3/18/2010 11:26:19 am

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