SERVICE INSTRUCTIONS “PVWJ” C-FRAME PUMPS -064/ …...Hydraulic systems are hot. DO NOT TOUCH!...

Bulletin 947635 THE OILGEAR COMPANY 1

SERVICE INSTRUCTIONS“PVWJ” C-FRAME PUMPS -064/-076/-098/-130FOR TYPE “P-1NN” AND “P-LNN” PRESSURE

COMPENSATING CONTROLS

Figure 1. Typical Oilgear Type “P-1NN” and “P-LNN” Pressure Compensator Controls for “PVWJ” C-Frame Pump

PURPOSE OF INSTRUCTIONSThese instructions will simplify the installation,operation and maintenance of Oilgear type“P-1NN” and “P-LNN” 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 90011Proper Installation of Vertical Pumps .....................................................................Bulletin 90014PVWJ Open Loop Pumps, Application Guidelines ..............................................Bulletin 847085PVWJ Open Loop Pumps (All Frame Sizes) Service Instructions .......................Bulletin 947085PVWJ Open Loop Pumps, Sales ...........................................................................Bulletin 47085

PVWJ PUMP INSTALLATIONSPVWJ C Frame (PVWJ-064) w/ Rear Ports................................................................. DS-47486PVWJ C Frame (PVWJ-064) w/ Side Ports & w/ or w/o Thru Shaft............................. DS-47487PVWJ C Frame (PVWJ-076/-098/-130) w/ Rear Ports ................................................ DS-47488PVWJ C Frame (PVWJ-076/-098/-130) w/ Side Ports & w/ or w/o Thru Shaft ............ DS-47489

PVWJ PUMP CONTROL INSTALLATIONS“P-1NN” and “P-LNN” Pressure Compensator for PVWJ-064/-076/-098/-130............. DS-47986

OILG0250

Bulletin 947635

Issued: August 2006

THE OILGEAR COMPANY2300 South 51st Street

Milwaukee, Wisconsin 53219www.oilgear.com

Bulletin 947635

2 THE OILGEAR COMPANY Bulletin 947635

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 the Oilgear Company.Contact us at 414-327-1700 or visit ourwebsite: www.oilgear.com. Please contactus if you have 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 andplaced in a clean rag or container until theyare 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

© 2006 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 two 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 correct hoses, fittings, and adapterswith the correct SAE rating whenreplacing hoses to prevent possibleserious injury. Always replace hoses,fittings and adapters with replacementsthat have a proper, suitable, workingpressure rating. Replacement hoses mustbe of the correct length and must complywith the hose manufacturer’s andOilgear’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 they are fully supportedor blocked. 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” or “P-LNN” Controls Shown with Typical Pump

Figure 3. Curve Indicating Flow Versus Pressure for “P-1NN” or “P-LNN” Type Controls

A

B

OILG0251

RP

250 psi(17.2 bar)

750 psi(51.7 bar)

1500 psi(103.4 bar)

Rated PumpPressure

“P-LNN” AdjustmentRange

“P-1NN” AdjustmentRange

OILG0252PRESSURE

FLO

W


TROUBLESHOOTINGPROBLEM CAUSES REMEDY

Unresponsive or Unstable Control

Swashblock bearing surface and/or Saddle Bearings worn or damaged.

See appropriate pump service bulletin.Control Pin and/or hole in Swashblock worn significantly.

Saddle Bearing Locating Pins broken.

Fluid is contaminated. Inspect and clean if necessary. See bulletin 90007.

Control Piston orifice (732) plugged. Inspect and clean if necessary.

Contamination trapped between control piston (702) and piston bore is not allowing piston to move smoothly. Inspect and clean if necessary. Replace scored or

damaged parts.Contamination trapped between control spool (706) and spool bore is not allowing spool to move smoothly.

Faulty remote pressure compensator circuit components. Inspect and replace if necessary.

Hydraulic line between remote pressure compensator components and RP port of control is too long.

Shorten line length.

Insufficient control flow. Increase size of control piston orifice (732).

Insufficient Outlet Volume

Swashblock not stroking to desired displacement.

See appropriate pump service bulletin.

Low input drive speed.

Worn or grooved Cylinder Barrel and/or Valve Plate mating surfaces.

Failed Driveshaft.

Worn or damaged Piston Shoes or Swashblock.

Worn Pistons and/or piston bores.

Control Piston stuck off stroke. Inspect and replace if necessary.

Maximum Volume Stop adjusted incorrectly.Adjust Maximum Volume Stop CCW to increase outlet flow.

Pressure Compensator is set too close to operating pressure.Adjust Pressure Compensator setting CW to increase setting.

Destrokes at low pressure

Pressure compensator adjustment not set correctly.Adjust Pressure Compensator setting CW to increase setting and retorque jam nut (715).

Control Piston orifice (732) plugged. Inspect and clean if necessary.

Damaged or fractured control spring (items 708 and/or 709).

Inspect and replace if necessary.Severely worn control spool (706) and/or spool bore.

Damaged or fractured control piston spring (item 703).

Faulty remote pressure compensator circuit components.

Excessive peak pressure

Pressure Compensator is set too high.Adjust Pressure Compensator setting CCW to decrease setting.

Minimum Volume Stop is set too high.Adjust Minimum Volume Stop CCW to decrease outlet flow.

Fluid is contaminated. Inspect and clean if necessary. See bulletin 90007.

Swashblock bearing surface and/or Saddle Bearings worn or damaged.

See appropriate pump service bulletin.

Contamination trapped between control piston (702) and piston bore is not allowing piston to move smoothly. Inspect and clean if necessary. Replace scored or

damaged parts.Contamination trapped between control spool (706) and spool bore is not allowing spool to move smoothly.

Hydraulic line between remote pressure compensator components and RP port of control is too long.

Shorten line length.

Faulty remote pressure compensator circuit components. Inspect and replace if necessary.

Restriction in drilled passages between pump outlet port and control spool.

Inspect and clean if necessary.


PRINCIPLE OF OPERATIONThe pressure compensator control ensuresmaximum pump flow until the system reaches thecontrols preset pressure setting. The control thenregulates the pump output flow to match the flowrequirements of the system, while maintaining thepreset output pressure.

When the system pressure exceeds thecompensator control setting, or the system nolonger requires flow, the control de-strokes thepump while maintaining the preset pressure.

“P-1NN” controls can be adjusted from 750 psi(51,7 bar) working pressure up to the maximumpressure rating of the applicable pump. “P-LNN”controls can be adjusted from 250 psi (17,2 bar) upto a maximum of 1500 psi (103,4 bar).

Figure 4. Swashblock at Full Delivery and “P-1NN” or “P-LNN” Controls at Maximum Volume Stop

OILG0253


LINE MOUNTED REMOTE PRESSURE CONTROL FOR TYPE “P-1NN” AND “P-LNN” PUMP CONTROLS - VSR (REMOTE SEQUENCE VALVE)Remote operation of “P-1NN” and “P-LNN” controlscan be accomplished by installing an Oilgear VSRModule at locations shown in the control circuit.Use module L51542 for units rated continuously for4000 psi (275,8 bar) or less. Use L51542-1 forunits rated above 4000 psi (275,8 bar).

To minimize case leakage and power loss,plug the control drain port with a #10-24UNC setscrew to maintain the standard“P-1NN” or “P-LNN” control case leakage.The plug will increase response time.Standard response time can be obtained byinstalling a .040 inch (1,0 mm) orificeinstead of plugging it.

Figure 7. “P-1NN” and “P-LNN” Control Drain Port Location

The compensator setting on the pumpcontrol must be set at least 200 psi (13,8bar) higher than the required pressuresetting of the remote compensator moduleto prevent the pump compensator controlfrom interacting with the remotecompensator module.

Figure 5. “P-1NN” and “P-LNN” Control Circuit with Remote Pressure Control

NOTE

DRAIN PORT AS VIEWED FROMUNDERSIDE OF CONTROL BODY.

OILG0255

NOTE

A

B

IN OUT

DR

VSRMODULE

ORIFICEOR PLUG

RP

OILG0254


SCREW AND PLUG TORQUES FOR CONTROLS

CONTROL O-RING SEALS

Item Number Description Head Type & Size Tightening Torque

601 SAE #2 Plug 1/8" Internal Hex 45 in.-lbs (5 N·m)

603 SAE #4 Plug 3/16" Internal Hex 120 in.-lbs (14 N·m)

606 SAE #8 Plug 5/16" Internal Hex 45 ft-lbs (61 N·m)

711 PC Adjuster Screw LHCS 3/32" Internal Hex 57 in.-lbs (6 N·m)

714 Adjuster Plate Screw 5/32" Internal Hex 80 in.-lbs (9 N·m)

720 Max. or Min. Volume Stop Housing 7/8" External Hex 50 ft-lbs (68 N·m)

722 End Cap Screws 3/16" Internal Hex 120 in.-lbs (14 N·m)

723 Control Body Screws 1/4" Internal Hex 30 ft.-lbs (41 N·m)

732 Control Piston Orifice 3/32" Internal Hex 20 in.-lbs (2.3 N·m)

Item Number

ARP 568 Uniform Size

Number

Shore A Durometer

1010 -010 90

1011 -011 90

1113 -113 90

1129 -129 90

1242 -242 70

1902 -902 90

1904 -904 90

1908 -908 90

C-Frame PVWJ -064/-076/-098/-130 “P-1NN” and “P-LNN”


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, bulletin number anditem number. Specify type of hydraulic fluid toensure seal and packing compatibility.

Parts drawings may not be identical toOilgear drawings referenced.

PVWJ-064/-076/-098/-130 PRESSURE COMPENSATOR CONTROLS (“P-1NN” STANDARD & “P-LNN” LOW PRESSURE CONTROLS)

Item Description

COMMON PARTS GROUP601 SAE#2 Plug603 SAE#4 Plug606 SAE#8 Plug701 Control Block702 Control Piston703 Control Piston Spring704 Piston Stop705 End Cap706 Pressure Compensator Control Spool707 Spring Seat708 Pressure Compensator Spring (Outer)709* Pressure Compensator Spring (Inner)710 Control Plug711 Screw712 Shims713 Adjuster Plate714 Screw715 Jam Nut716 Pressure Compensator Adjustment Screw717 Min. Volume Stop Stem718 Max. Volume Stop Stem719 Jam Nut720 Volume Stop Housing721 Control Pin722 Screw, End Cap723 Screw, Control Body732 Orifice1010 O-Ring1011 O-Ring1113 O-Ring1129 O-Ring1242 O-Ring1902 O-Ring1904 O-Ring1908 O-Ring

*Only used in P-1 Control.

NOTE



SERVICE KITSPVWJ Service KitsReference 519975-301SERVICE KIT, Figures 8 & 9

Document Number: 519975-SK3

Revision: New

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

Main Control Body KitsPVWJ-064 K50434-100 A1 701, 706

PVWJ-076/-098/-130 K50434-200 A1 701, 706

Control Piston KitsAll Models K50485 A1 702, 732

Pressure Compensator SpoolsPVWJ-064 50015-100 A1 706

PVWJ-076/-098/-130 50015-200 A1 706

Control Spring KitsP-LNN (All Models) K50036-105 A1 703, 708

PVWJ-064 P-1NN K50036-108 A1 703, 708, 709

PVWJ-076/-098/-130 P-1NN K50036-111 A1 703, 708, 709Control PinsAll Models 51339-2 A1 721

Volume Stop KitsMaximum Volume Stop (All Models) K50590 A1 718, 719, 720, 1011, 1908

Minimum Volume Stop (All Models) K50590-300 A1 704, 705, 718, 719, 720, 1011, 1020, 1908

Pressure Compensator Adjuster KitsAll Models K50660-300 A1 710, 711, 712, 713, 715, 716, 1113

Control Seal KitAll Models K50824-300 A1 1010, 1011, 1113, 1129, 1242, 1902, 1904, 1908



Figure 8. Parts Drawing for “P-1NN” and “P-LNN” Control (519975-301 sheet 1)

MAXIMUM AND MINIMUM VOLUME STOPThe maximum volume stop can be adjusted toattain a maximum volume from full to 25% of fullflow. The pump can be de-stroked from full to 25%flow with 13-1/2 turns of the volume stop. One turnclockwise will decrease maximum pump outlet flow4%.

The minimum volume stop can be adjusted toattain a minimum volume from zero to 70% of fullflow. The adjustment requires 12-1/2 turns to gofrom zero to 70% of full flow. One turn clockwisewill increase minimum pump outlet flow 4%.

603 1904

601 1902

705703

715713710 711708 709707706

702

716

606 1908

STANDARD CONFIGURATIONFOR P-1NNNN & P-LNNNN

732

720719

OPTIONAL MAXIMUMVOLUME STOP

FOR P-1NNSN & P-LNNSN

1908 71871972010111908 7051129704

712

1129

1113701

718 1011

OPTIONAL MINIMUMVOLUME STOP

FOR P-1NNSA & P-LNNSAOILG0273



Figure 9. Exploded Parts Drawing for “P-1NN” and “P-LNN” Control (519975-301 sheet 2)

"RP

" P

OR

T

713

714

RE

F

1113

1129

1011

719

720

1908

718

1011

722

705

1129

704

732

712

710

703

706

601

1902

718

719

720

1908

716

722

701

708

709

707

603

1904

603

1904

702

723

705

1242

1010

711

721

RE

FR

EF

715

606

1908

OIL

G02

74



NOTES

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________


NOTES

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________


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.

THE OILGEAR COMPANY2300 South 51st Street

Milwaukee, Wisconsin 53219www.oilgear.com

Issued: August 2006

SERVICE INSTRUCTIONS “PVWJ” C-FRAME PUMPS -064/ …...Hydraulic systems are hot. DO NOT TOUCH!...

Documents

Transcript of SERVICE INSTRUCTIONS “PVWJ” C-FRAME PUMPS -064/ …...Hydraulic systems are hot. DO NOT TOUCH!...