OilGear A2 Series User manual

THE OILGEAR COMPANY
905 South Downing Street
Fremont, NE 68025 USA
www.oilgear.com
Issued: May 2019
CONTROL SERVICE MANUAL
Bulletin 948675A
Bulletin 948675A
Figure 1. Typical Oilgear Type “P-1NN” Single Pressure Compensator
Control for PVG- Pumps
PURPOSE OF INSTRUCTIONS
These instructions will simplify the installation,
operation, troubleshooting and maintenance of
Oilgear type “P-1NN” Single Pressure
Compensator controlled units.
This material will inform you about the basi
c
construction, principle of operation and servic
e
parts listings. Some controls may be modified fo
r
specific applications from those described in
this
bulletin and other changes may be made withou
t
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 Pump - 180 Service Instructions................................................................................................... Bulletin 948034
PVG Open Loop Pumps, Sales ............................................................................................................Bulletin 47019-K
PVG 180 PUMP INSTALLATIONS
Single Pressure Compensator “P-1NN,” Installation ........................................................................ Data Sheet 48377
Through Shaft Basic Pump, Installation .......................................................................................... Data Sheet 48376
Gear Pump, Installation ..................................................................................................................... Data Sheet 47945
Dual Pump 2-Bolt SAE Adapters, Installation ....................................................................................Data Sheet 48387
Dual Pump 4-Bolt SAE Adapters, Installation ....................................................................................Data Sheet 48388
SERVICE INSTRUCTIONS FOR
“P-1NN” SINGLE PRESSURE COMPENSATOR
FOR PVG-180 PUMP, A2 SERIES CONTROL

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED Bulletin 948675A
2
Bulletin 948675A
CONTROL SERVICE MANUAL
Table of Contents
Safety First ..........................................................................................................................3 - 5
Circuit Diagram / Control Behavior Curve for ““P-1NN” Control .................................................... 6
Troubleshooting........................................................................................................................7
Principle of Operation: Starting / Raising Pressure ..........................................................8 - 10
Principle of Operation: Compensating Pressure (Unloading)........................................... 11 -12
Screw & Plug Torques Control O-Ring Seals Item Number List............................................. 13
Parts List.................................................................................................................................14
Control Service Kits................................................................................................................15
Parts Exploded Views......................................................................................................16 - 17
Notes ...............................................................................................................................18 - 19
Spare Parts Availability...........................................................................................................20

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED 3
Bulletin 948675A
Bulletin 948675A
Safety First
CONTROL SERVICE MANUAL
Read and understand this entire instruction sheet
before repairing or adjusting your Oilgear product.
Those
who use and maintain this equipment must
be
thoroughly trained and familiar with the product.
If
incorrectly used or maintained, this product and
its equipment can cause severe injury.
SAFETY SYMBOLS
The
following signal words are used in this
instruction sheet to identify areas of concern where
your
safety may be involved. Carefully read the text
and
observe any instructions provided to ensure
your safety
.
THIS SIGNAL WORD INDICATES AN IMMI-
NENTLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, WILL RESULT
IN DEATH OR SERIOUS INJURY.
This signal word indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury.
This signal word indicates that a potentially
hazardous situation exists which, if not
avoided, may result in damage to
equipment or minor personal injury.
While not directly relevant to the topic being
discussed, the NOTE is used to emphasize
information provided, or provide additional
information which may be of benefit.
This service information is designed for
the maintenance of your Oilgear product.
It contains the information on the correct
procedures determined by Oilgear for the
safe manner of servicing. Always keep
this instruction sheet in a location where it
is readily available for the persons who
use and maintain the product. Additional
copies of this instruction sheet are
available through Oilgear. Contact us
on our website: www.oilgear.com.
Please contact us if you have any
questions regarding the information
in this instruction bulletin.
The cleanliness of working on this pump
control or the hydraulic system
is
extremely important to the safety an
d
reliability of the pump and the system
.
Always make sure the fittings are clean
on
the outside before removing them
from
their connections, are capped and plugge
d
when removed, and are placed in a clea
n
rag or container until they are reinstalled.
Some service operations may require
special tools or equipment. If you require
information on these items, please contact
Oilgear before attempting these repairs
and service operations.
Read, understand and follow the safety
guidelines, dangers and warnings
contained in this instruction sheet to
promote reliable operation and prevent
serious personal injury.
DO NOT attempt to service this machinery
in an environment where safety regulations
are not established and in place.
DO NOT operate the hydraulic system if a
leak is present. Serious injury may result.
Hydraulic systems operate under very high
pressure. Hydraulic fluid escaping from a
pressurized system can penetrate
unprotected body tissue. DO NOT inspect
for hydraulic leaks with bare hands or
other exposed body parts. As a minimum,
wear leather gloves prior to inspecting for
leaks and use cardboard or wood. If leaks
are present, relieve pressure and allow
system to cool prior to servicing. If injured
by escaping hydraulic oil, contact a
physician immediately. Serious
complications may arise if not treated
immediately. If you have questions
regarding inspecting for hydraulic leaks,
please contact Oilgear prior to servicing.
DANGER
! !
!
WARNING
CAUTION
NOTE
!
WARNING
NOTE
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED
4Bulletin 948675A
Bulletin 948675A
Safety First
CONTROL SERVICE MANUAL
Hydraulic
hoses and tubing must be
inspected
on a daily basis for leaks, cuts,
abrasions,
damage and improper
clearance
along any mounting frame for
hidden
damage before the unit is put into
service. Replace damaged hoses or hose
s
you
suspect are damaged before the
system is returned to service! Hoses must
be
replaced every 2 years. Failure to
properly
inspect and maintain the system
may result in serious injury
.
Hydraulic
systems are hot. DO NOT
TOUCH!
Serious personal injury may
result
from hot oil. When you have
completed
working on the hydraulic
system,
thoroughly clean any spilled oil
from
the equipment. Do not spill any
hydraulic
fluids on the ground. Clean any
hydraulic
fluids from your skin as soon as
you
have completed maintenance and
repairs.
Dispose of used oil and system
filters as required by law.
Use
hoses, fittings and adapters with the
correct
SAE rating when replacing hoses
to
prevent possible serious injury. Always
replace
hoses, fittings and adapters with
replacements
that have a proper, suitable,
working
pressure rating. Replacement
hoses
must be of the correct length and
must
comply with the hose
manufacturerʼs
and Oilgearʼs installation
guidelines and recommendations.
Hydraulic
hoses have the SAE ratings
marked
on the hose to assist you in
selecting
the correct hose. The same
manufacturer
must supply any replacement
hydraulic
hoses and fitting assemblies. As
an
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 hose
failure.
This can cause serious injury.
Please
contact Oilgear for assistance when
required.
Hydraulic cylinders can be holding a
function in a certain position when the
pump is off. An example of this is a
function being held in the lift or partial lift
position by the cylinders. If a hydraulic
line is removed or the hydraulic circuits or
controls are being worked on, gravity may
allow the function being held in position to
drop. All workers and personnel must
remain clear of these areas when working
on or operating the hydraulic system.
Block and secure all devices and
functions which apply before beginning
work or operation. Failure to comply with
this can result in serious injury or death.
Any hydraulic pipe which is replaced must
conform to SAE J1065 specifications. If
incorrect hydraulic pipe is installed, the
hydraulic system may fail, causing
serious injury. Damaged or leaking
fittings, pipes or hoses must be replaced
before the system is returned to service.
DO NOT heat hydraulic pipe. The carbon
content of this steel tube is such that if
heated for bending, and either water or air
quenched, the pipe may lose its ductility
and thereby be subject to failure under
high pressure conditions. Serious injury
can result. Damaged or leaking pipes
must be replaced before the system is
returned to service. Please contact Oilgear
if you require assistance or have
questions.
All hydraulic pressure must be
relieved
from the hydraulic system prior to
removing any components from the
system. To relieve the hydraulic pressure
from the hydraulic system, turn off the
motor and operate the control panel with
the key in the ON position. Failure to
comply can result in serious injury. If yo
u
have any questions concerning
relieving
the hydraulic pressure from the system,
please contact Oilgear.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED 5
Bulletin 948675A
Bulletin 948675A
Safety First
CONTROL SERVICE MANUAL
Hydraulic
components can be heavy. Use
caution
while lifting these components.
Serious
personal injury can be avoided
with pr
oper handling of the components.
Please
contact Oilgear if you require
assistance,
when performing hydraulic
test
procedures, use the proper hydraulic
gauges.
Installing an incorrect test gauge
could
result in serious injury if the gauge
fails.
Use properly rated hydraulic hoses
to
allow the test gauge to be read away
fr
om moving parts and functions.
Increasing
hydraulic pressure beyond the
recommendations
may result in serious
dama
ge to the pump and system or
serious
personal injury and may void the
Oil
gear Warranty. If you have questions
concerning
hydraulic pressures or testing
pr
ocedures, please contact Oilgear before
attempting
the test procedures or making
adjustments
.
An
Oilgear pump must not be modified in
an
y way without authorization from
Oil
gear. Modifications may not comply
with
safety standards, including ANSI
saf
ety standards, and may result in
serious
personal injury. Please contact
Oil
gear if you require assistance.
DO
NOT enter under hydraulic supported
equipment
unless they are fully supported
or
blocked. Failure to follow this procedure
can result in serious injury or death.
Any Oilgear pump safety decals must be
replaced anytime they are damaged,
missing, or cannot be read clearly. Failure
to have proper decals in place can result
in serious injury or death. (If you require
safety decals, please contact Oilgear for
replacement safety decals, at no charge.)
Be sure everyone is clear of the area
around the hydraulic system before
operating after servicing. Remain attentive
at all times when operating to check your
work until you are completely sure it is
safe to return to service. Failure to heed
this warning may result in serious
personal injury or death.
Wear the proper protective clothing when
operating, servicing or maintaining the
hydraulic system or the Oilgear pump. Wear
the correct protective gear, safety glasses,
gloves, and safety shoes. Serious injur
y
can result without proper protective gear.
Make sure to keep hands and feet and
other parts of your body clear of revolving
or moving parts. Failure to comply can
cause serious injury.
DO NOT wear watches, rings, or jewelry
while working with electrical and
mechanical equipment. These items can
be hazardous and can cause serious and
painful injuries if they come into contact
with electrical wires, moving parts, or
hydraulic equipment.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED Bulletin 948675A
6
Bulletin 948675A
CONTROL SERVICE MANUAL
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
1
B
GPA
2PO1PO
OP 6
OP 3OP 4
RP1
1A
OP 14
OILG0331
FLOW
PRESSURE Related Pump
Pressure
OILG0380

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED
Bulletin 948675A 7
Bulletin 948675A
CONTROL SERVICE MANUAL
TROUBLESHOOTING
PROBLEMCAUSESREMEDY
Unresponsive or
Unstable Control
Swashblock bearing surface and/or saddle bearings worn or
damagedReferto948034 Pump Service Instructions.
Fluid is contaminatedInspect and clean if necessary. Refer to Filtration
Recommendations 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 poppet Inspect 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
Referto948034 Pump Service Instructions.
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 pressure Adjust pressure compensator CW to increase
pressure.
Control piston stuck off stroke Inspect 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 correctly Adjust 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
damagedReferto948034 Pump Service Instructions.
Pressure compensator adjustment not set correctly Adjust 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.

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED Bulletin 948675A
8
Bulletin 948675A
CONTROL SERVICE MANUAL
PRINCIPLE OF OPERATION
Oper
ation for a typical pump is described. Section
diag
rams are a representation of typical pumps
with “P
-1NN” control.
Functionall
y, the swashblock (and resultant
displacement)
is positioned by two opposite acting
control
pistons (unloading control piston and bias
co
ntrol piston).
See
control parts drawing for actual configuration
and
location of part assemblies, orifices,
connections and ports.
STARTING
The bias spring (329)positions the control piston
s
and connected pump swashblock so that the
pump
is at maximum displacement to raise pressure
in
the system.

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED
Bulletin 948675A 9
Bulletin 948675A
CONTROL SERVICE MANUAL
RAISING PRESSURE - LOADING
Pump
outlet pressure is ported to the contro
l
through
Port “OP 1” to the control spool (305)an
d
to
the bias control piston (303). Outlet pressure
is
also
transmitted through orifice Port “OP 2,
”
allowing
the pressure acting on either end of th
e
co
ntrol spool (305) to be equal. In this
condition,
the
control spool (305) is held in position only
by
the sp
ring (328).
The
outlet pressure through Port “OP 2” is furthe
r
trans
mitted through Port “OP 3” and Port “OP 4”
to
the adjustable pressure compensator relief valve.

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED Bulletin 948675A
10
Bulletin 948675A
CONTROL SERVICE MANUAL
Figure 4. Raising Pressure - Loading
TO SYSTEM
UNLOADING
CONTROL
BIAS
CONTROL
OP 4
OP 3
OP 2
OP 14
OPTIONAL
OP 1
OP
6
(328)
(305)
PRESSURE
COMPENSATOR
RELIEF VALV E
CONTROL PIN
SWASHBLOCK
(329)
(303)
OILG0474

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED
Bulletin 948675A 11
Bulletin 948675A
CONTROL SERVICE MANUAL
COMPENSATING PRESSURE - UNLOADING
When
pressure on the relief valve poppet (307)
ex
ceeds the presetting of the relief valve spring
(327)
, the relief valve poppet (307)moves off seat
(308)
and allows flow through the relief valve to
dr
ain. Pressure on the spring end of the control
sp
ool (305) is decreased, causing a pressure
diff
erential across the spool (305). The pressure
diff
erential forces the control spool (305) to shift
and
compress the spring (328). Outlet pressure is
then
ported to the unloading control piston (302),
and
fluid behind the bias control piston (303)is
po
rted to drain. Pump displacement will decrease
to
maintain system pressure as set by the relief
va
lve adjuster (310).
HOLDING PR
ESSURE
If
the system pressure drops below the preset
compens
ating pressure, the relief valve poppet
(307)
seats and closes the path to drain. Pressure
on
either side of the control spool (305)will
become
equal and the spring (328)will shift the
spoo
l(305)to the original position (Figure 4).
Fluid
from the unloading control piston (302)is
then
ported to drain and outlet pressure is ported
to
the bias control piston (303). Pump
displacement
will increase until the relief valve
setting 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” .062 orifice
“OP 14”Orifice not used (standard)
Orifice
Number
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"

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED Bulletin 948675A
12
Bulletin 948675A
CONTROL SERVICE MANUAL
Figure 5. Compensating Pressure - Unloading
TO SYSTEM
UNLOADING
CONTROL
BIAS
CONTROL
OP 4
(308)
OP 3
OP 2
OP 14
OPTIONAL
OP 1
OP
6
(328)
(305)
(327)
(310)
(307)
CONTROL PIN
SWASHBLOCK
(303) (302)
OILG0475

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED
Bulletin 948675A 13
Bulletin 948675A
CONTROL SERVICE MANUAL
CO
NTROL O-RING SEALS
Fastener or Plug
Item Number Description Head Type & Size
306 SAE #8 Part 7/8" external
308 SAE #6 Part 7/16" external
309 SAE #10 Part 1" external
315A 1/2-13 SHCS x 2.00" lg 3/8" internal
315B 1/2-13 SHCS x 2.50" lg 3/8" internal
3161/2-13 SHCS x 1.50" lg 3/8" internal
3191/16 NPT Plug 5/32" internal
321 SAE #4 Plug 3/16" internal
322 SAE #8 Part 7/8" external
323 SAE #12 Plug 9/16" internal
3251/16 NPT Plug 5/32" internal
342 SAE #3 Plug 1/8" internal
720 SAE #12 Part 1 1/4" external
Tightening
Torque
50 ft-lbs (68 Nm)
200 in-lbs (23 Nm)
80 ft-lbs (108 Nm)
100 ft-lbs (136 Nm)
100 ft-lbs (136 Nm)
100 ft-lbs (136 Nm)
48 in-lbs (5 Nm)
120 in-lbs (14 Nm)
50 ft-lbs (68 Nm)
85 ft-lbs (115 Nm)
48 in-lbs (5 Nm)
45 in-lbs (5 Nm)
120 ft-lbs (163 Nm)
Viton or Buna EPR
3141 140/70 140/80
3303 013/90 013/80
3311 014/90 014/80
3331 906/90 906/80
3342 908/90 908/80
3351 910/90 910/80
3361 912/90 *912/80
3371
3383 904/90 *904/80
3452 903/90 *903/80
3991
1014 1014/90 014/80
1912 1912/90 912/80
Item
Number Quantity ARP 568 Size Number / Shore A Durometer
014/Teflon Back Up Ring
014/Teflon Back Up Ring
*Pumps with Buna seals use Viton for all SAE plugs
SCREW AND PLUG TORQUES FOR PVG-180 “P-1NN” CONTROL

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED Bulletin 948675A
14
Bulletin 948675A
CONTROL SERVICE MANUAL
PARTS LIST FOR PVG-180
“P-1NN” CONT
ROL
Pa
rts used in these assemblies are per Oilgear
specifications
. Use only Oilgear parts to ensure
compatibility
with assembly requirements. When
order
ing replacement parts, be sure to include
pump
type and serial number, and bulletin number
and
item number. Specify type of hydraulic fluid to
ensure seal and pa
cking compatibility.
Item
Number Quantity Description
3011
Control Housing
3021Control Piston
3031Bias Piston
3041End Cap
3051Spool
3061Plug
3071Poppet
3081Seat
3091Bonnet
3101Adjusting Screw
3124Shim
315A 2Screw
315B 1Screw
3164Screw
3181Nut
3191Orifice Plug
3213Plug
3221Plug
3231Plug
3251Orifice Plug
3271Spring
3281Spring
3291Spring
3401Plug, Permanent
3422Plug
3482Pin
7181Adjusting Screw
7191Nut
7201Bonnet

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED
Bulletin 948675A 15
Bulletin 948675A
CONTROL SERVICE MANUAL
PVG- P-1NN Control Service Kits
Reference: 167Assʼy Drwg
Document Number: 520167-SK1
Revision: 0 8
Sheet 1 of 1
DescriptionKit Number Design
Series
,A2
Items Included (quantity is 1 unless noted)

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED Bulletin 948675A
16
Bulletin 948675A
CONTROL SERVICE MANUAL
Figure 6. Exploded Parts Drawing for PVG-180 “P-1NN” Single
Pressure Compensator Control(520167-831 sheet 1)

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED
Bulletin 948675A 17
Bulletin 948675A
CONTROL SERVICE MANUAL
Figure 7. Cross Section Parts Drawing for PVG-180 “P-1NN” Single Pressure
Compensator Control(520167-831 sheet2)

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED Bulletin 948675A
18
Bulletin 948675A
CONTROL SERVICE MANUAL
NOTES

© 2019 THE OILGEAR COMPANY - ALL RIGHTS RESERVED
Bulletin 948675A 19
Bulletin 948675A
CONTROL SERVICE MANUAL
NOTES

THE OILGEAR COMPANY
905 South Downing Street
Fremont, NE 68025 USA
www.oilgear.com
Issued: May 2019
CONTROL SERVICE MANUAL
Bulletin 948675A
Bulletin 948675A
SPARE PARTS AVAILABILITY
Prepare for your future needs by stocking Oilgear
original factory parts. Having the correct parts and
necessary skills “in-plant” enables you to minimize
“down-time.” Oilgear has developed parts kits to
cover likely future needs. Oilgear Field Service
Technicians are also ready to assist you and your
maintenance people in troubleshooting and
repairing equipment.