Service Manual for Hydraulic Vane Pumps Flange
Contents
1. Service Manual for Hydraulic Vane Pumps Flange Mounted PVC Series PVC PSCF 09GRM 01 Flanged Series Pump PVC PSCF 12ERM 01 Flanged Series Pump Contents INstallatiOn anaran raain arar aa EAEE a raa aaa taas 1 Start Up procedures sssrin Operating instructions Parts listini ansdina Pump repair procedures sss ssssssserssesrsrrrsssssrnnressnrnrieesnnnnneennntnneennnnrineenans 5 Installation CAUTION Before performing any service opera tion on any pump be sure that all pressure has been relieved from BOTH SIDES of the system CAUTION Before performing any service operation on any pump disconnect or lock off power supply CAUTION Before starting pump be sure that any resulting machine function will not endanger persons or equipment gt gt gt Product identification Each pump has an Ordering Code stamped on its nameplate See Figure 1 for the location of the Ordering Code Rexroth gt L e ee SM PSCF 07 03 1 06 Th E 7 i fs Ti gt rh x A ii r r TA PVC ORDERING CODE PVC PSCF 12 ERM 01 Figure 1 2 06 Bosch Rexroth Corp Industrial Hydraulics Installation continued Pump drive and mounting When mounting the pump and motor care must be taken to align the pump and motor shafts within 003 T I R direct inline through a jaw type flexible web coupling This is recommended for all Rexroth pumps Tire type flexing elements and chain typ2. Straight Thread Plug 1 41 Spring Retainer 1 42 Shim 005 A R 43 Shim 0149 A R 66 Name Plate 1 67 Self Tapping Screw 6 68 Escutcheon Rotation Arrow 80 Dowel Pin 2 92 SAE O Ring Plug 1 99 Thrust Screw Plug Kit 1 Not Grease Union 76 UNOBA EP2 A R Shown Grease LED Plate 250 24 A R Parts shown for reference only not available for individual sale ITEM NO NO CODE DESCRIPTION REQ 1 Pump Body 1 2 Cover 1 3 Rotorshaft 1 4 Port Plate 1 5 Thrust Plate 1 6 Pressure Ring 1 i Repair parts kit 7 Vane Kit Set of 13 1 epair parts S 8 Spring Seat 1 Viton seal kit Governor Spring 1 Includes items Model Kit No 10 Follower Spring 1 I mm 13 15 17 24 28 30 37 55 amp 99 O09GRM 01 R978715448 a Ring Shoe een i A SER 01 R978715448 13 Teflon Seal Ring 1 15 vion O Ring 1 Complete rebuild kit 16 Viton O Ring 1 17 Viton O Ring 1 Includes items Model Kit No 18 Soc Hd Cap Screw 4 3 4 5 6 7 21 amp Seal kit 09GRM 01 R978715451 p 19 Thrust Screw 1 12ERM 01 R978715452 SM PSCF 07 03 Service Manual Pump repair procedures Industrial Hydraulics Bosch Rexroth Corp 5 06 NOTE Disassembling pump to change components or for any other reason may void the warranty Refer to Policy Statement and Discounts Summaries Disassembly procedure 1 Remove the key 22 in the rotor shaft keyway 2 A small amount of oil may remain in the pump Remove the four
3. adjusting screw is directly opposite the pressure adjusting screw see parts page item number 55 The adjusting screw has a right hand thread turning the screw clockwise decreases the maximum volume turning the screw counterclock wise increases the maximum volume Pumps are set at a maximum rated volume at the factory unless otherwise specified Stop adjustment of the volume screw when pressure begins to drop See Sales Catalog for complete pump performance specifications Adjustment procedures To adjust the maximum output volume use the following steps 1 Set the pump at minimum pressure 2 Hand tighten the volume screw until it touches cam ring NOTE The pump should be at full flow for this step 3 See Pressure and Volume Adjustment Sensitivity chart below 4 Deadhead the pump turn the volume screw the proper number of turns to obtain the flow desired 5 Return pump to flow condition and check flow rate If output flow is incorrect switch pump to deadhead and readjust per above CAUTION Turning the maximum volume control in too far can force the cam ring over center and destroy the pump 4 06 Bosch Rexroth Corp Industrial Hydraulics Service Manual SM PSCF 07 03 Parts list ITEM NO NO CODE DESCRIPTION REQ 21 Bushing Bearing 2 22 Key 1 23 Spring Pin 3 24 Viton Lip Seal 1 30 Viton Pressure Adj Screw Ass y 1 31 Spring Pin 1 40 Viton
4. cover bolts and slide the cover back far enough on the shaft to break the seal between the housing and cover to allow the pump to drain 3 Remove the cover Take care to avoid damage to the bearing with the end of the shaft when the cover is removed 4 The port plate 4 may come out with the cover Do not let it drop off the locating pins 5 Remove the vanes 7 with a long nosed pliers or tweezers there is one vane in each slot 13 vanes total 6 Remove the rotorshaft 3 from the pump Be sure that the key 22 has been removed from the keyway so that it will not damage the shaft seals when the rotorshaft is removed 7 Turn the pressure adjustment screw 30 counterclockwise to release the tension on the governor spring 8 Remove the pressure ring 6 spring shoe 11 governor spring 9 retainer 41 and follower spring 10 9 Ifthe shaft seals 24 are to be removed they should be pushed out from the inside of the housing at this time Care must be taken not to damage the journal bearing in the housing while the shaft seals are being removed It is recommended that the shaft seals be replaced whenever the pump is disassembled for maintenance The seals cannot be reused once they have been removed 10 The journal bearings 21 in the pumps are assembled with a press fit If they are to be removed at this time the bearing in the housing should be pressed out from the front The cover bearing should be pulled out usin
5. or connect the pump outlet line directly to tank Jog the motor on and off several times on two seconds off three seconds until the pump is primed Check pump for proper direction of rotation during the jogging 7 After the pump has been primed run it for several minutes at lower than normal pressures with an open or intermittently open system which permits oil flow This will purge entrapped air from the pump and system 8 Neither volume adjustment nor pressure adjustment should be adjusted until the pump has been primed and running and air is purged 9 After air has been purged from the system the system can be closed and the pump adjusted to the required operating pressure 10 If necessary the volume adjustment can be adjusted to the required operating pressure 11 When replacing pumps the suction screen in the reservoir must be removed and thoroughly cleaned Also the suction line from the reservoir to the pump should be flushed inside and out to remove any contaminants Pieces of metal from a damaged pump can back up into this line If they are not removed they will be drawn into the new pump and destroy it Start unit by using proper pump start up procedure items 1 through 10 CAUTION If both pressure and volume modifications are supplied on the pump the pressure should be adjusted before the volume Volume should be adjusted at minimum pump pressure or at deadhead Stop adjustment at the volume screw when pr
6. aulics 2315 City Line Road Bethlehem PA 18017 2131 Phone 610 694 8300 Fax 610 694 8467 www boschrexroth us com 13 Adjust the pressure adjustment screw until it just touches the spring and then give it one more turn clockwise 14 Turn pump upside down Pour one cup of good grade hydraulic fluid into the intake port while slowly rotating the shaft in the direction shown by the rotation arrow 15 The pump is now ready to test Refer to front of this manual for start up procedure lt t 0 07 1 78 mm One Vane Thickness 2D The data specified above only serves to describe the product No statements concerning a certain condition or suitability for a certain application can be derived from our information The details stated do not release you from the responsibility for carrying out your own assessment and verification It is important to remember that our products are subject to a natural process of wear and aging All rights reserved No part of this document may be reproduced or stored processed duplicated or circulated using electronic systems in any form or by means without the prior written authorization of Bosch Rexroth Corporation
7. case drain should be connected directly to the tank Pressure in excess of 10 psi in the case drain line can result in shaft seal leakage It is recommended that the case drain be returned to the tank by a separate 3 8 inch line Service Manual SM PSCF 07 03 Start up procedures The following instructions apply for initial startup of the hydraulic pump After an extended shutdown period start with item 5 CAUTION Never start a new pump installation against a blocked system 1 Check the name plate for model number and rpm The arrow on the pump casting indicates direction of rotation 2 Pump suction line should extend below the lowest point of oil level but not less than two inches above reservoir bottom 3 The pump and motor shafts must be aligned within 003 inches See Pump Drive and Mounting directions above for restrictions 4 Connect the case drain directly to tank or to a heat ex changer if the pump will be deadheading for long periods of time during operation using a full size line corresponding to the case drain in the pump or manifold If connected to a heat exchanger the case drain line should be protected with a 10 psi maximum relief valve in parallel with the heat exchanger No other return lines should be connected in common with the case drain return 5 Rotate pump and motor by hand to insure free rotation 6 Set the machine controls to open the circuit and allow free flow from the pump back to tank
8. e drives are not recommended With belt drives please consult factory To avoid axial and radical end loading of the pump shaft do not couple the pump and motor shafts rigidly Allow freedom at the coupling for the two shafts to ride independently To prevent end loading the space between the pump and motor shaft ends should be 1 2 inch for PVC pumps or as the coupling manufacturer specifies Piping and Reservoir The pump should be mounted with a minimum number of elbows or fittings The pump suction should be at least 1 inch tube pipe for PVC pumps For any system and combination of piping except High Water Based Fluids HWBF the vacuum at the pump inlet must not exceed seven inches of Mercury 5 inch Hg for fire resistant fluids HWBF Pumps are to have a positive inlet head in the range of 0 5 inch Hg to 20 inch Hg Piping should be done with pickled pipe or seamless tubing free of dirt and scale Do not use galvanized or other pipe that tends to flake off A 100 mesh screen 60 mesh for fire resistant and HWBF should be used on the pump suction line The screen should be located approximately two inches from the bottom of the tank All lines returning oil to the tank should discharge at least two inches below the minimum oil level and should be separated from the pump suction area by means of a baffle These lines should also include a 10 micron return line filter with the exception of the case drain line The pump
9. essure begins to drop SM PSCF 07 03 Service Manual Operatiang procedures Pressure and volume adjustments Pressure control Pressure and Volume Adjustment Sensitivity Industrial Hydraulics Bosch Rexroth Corp 3 06 Pump Size PVC PSCF PVC PSCF All pumps are adjusted to reduced pressure before shipment and 09 12 must be readjusted to the required system pressure after installa Pressure Code G 1500 psi E 1000 psi tion and start up Pressure Pressure change turn psi bar 260 17 9 235 16 2 a A Adjustment Maximum torque ft lbs kg M 6 8 0 83 5 0 0 89 The pressure adjusting screw is located at the end face of the i Flow change turn gpm lpm 4 6 17 4 compensator chamber See parts page item number 30 The Volume gt ae Approx min flow adj gpm lpm 1 25 4 7 adjusting screw has a right hand thread clockwise adjustment Adjustment Maximum torque ft lbs kg M 2 5 0 34 1 0 0 14 increases pressure counterclockwise reduces pressure A pressure gauge located at the pump must be used when making adjustment to insure the pressure settings do not exceed limits specified for the particular pump of maximum system pressure Make all pressure settings with pump operating against a closed circuit that is with the output of the pump blocked and then check pressure throughout the pump flow range Volume control Adjust volume at minimum pump pressure or at pump deadhead The volume
10. g an expanding type puller The bearings should not be reused once they have been removed 11 It is unlikely that further disassembly will be necessary in order to perform routine maintenance on the pump Reassembly procedure 1 Clean and inspect parts to determine which parts are worn enough to require replacement 2 Assemble the new bearings 21 in the housing and cover The bearing OD s should be lubricated before they are pressed in the bores Care must be taken to orient the split and the oil groove in the bearing as shown in the illustration below Spring Housing Thrust Sle Screw Oil Groove Positions Item 21 Bushing Bearing Orientation 3 After the bearings are in place check to see that the rotor shaft will fit into the bearings and provide a smooth turning fit If the shaft turns hard the bearings should be removed and the bore checked closely for nicks or burrs before pressing in the new bearings 4 Check all of the replacement parts for nicks or burrs and then lubricate them with clean oil before reassembly 5 Worn port and thrust plates should not be reground to clean up the wear surface If the plates are ground the assembly clearance will become excessive and the seal rings in the thrust plate may rupture Replace worn port and thrust plates if necessary 6 Assemble the springs and spring shoe ring and rotorshaft 7 To assure proper vane assembly place the vanes with the beveled edge ou
11. t against the pressure ring 8 Assemble the square seal rings into the cavity in the back of the thrust plate The soft rubber seal rings should be assembled first and the hard seat rings should be assembled on top of them Stretch the larger soft seal ring slightly so it clings to the ID at the cavity Apply clean oil or STP to the back of the thrust plate before it is placed in the locating pins in the body to help hold the parts together while they are assembled 9 Before fitting the cover into the housing check to assure that the bore in the port plate is concentric to the bearing bore in the cover If the bores are not concentric the port place must be relocated 180 on the locating pins 10 Assemble the cover and plate onto the housing and align the bolt holes Rotate the shaft as the bolts are tightened to assure that the vanes are not cocked 6 06 Bosch Rexroth Corp Industrial Hydraulics Pump repair procedures continued Service Manual SM PSCF 07 03 NOTE Disassembling pump to change components or for any other reason may void the warranty Refer to Policy Statement and Discounts Summaries 11 Torque the cover bolts to 50 Ibs ft The shaft should turn by hand when assembly is complete 12 Lubricate the ID of the shaft seal 24 and press it into the housing to the depth shown below Note the lip to the inside orientation of the seal lt t 25 6 35 mm Bosch Rexroth Corporation Industrial Hydr
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