Vickers. Service Data. Vane Pumps. Quiet Intra-Vane Single Pumps. 25V(T)-35V(T)-45V(T) Series 20 Design 282/283 Series
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1 Service Data Vickers Vane Pumps Quiet Intra-Vane Single Pumps 5V(T)-35V(T)-5V(T) Series 0 Design 8/83 Series Reprinted 6//96 I-35-S
2 Table of Contents Section Page I. Introduction A. Purpose of Manual B. General Information II. III. IV. Description A. General Principles of Operation A. General Installation and Operating Instructions A. Installation Drawings B. Mounting and Drive Connections C. Shaft Rotation D. Piping and Tubing E. Hydraulic Fluid Recommendations F. Sound Levels G. Overload Protection H. Start-Up V. Service & Maintenance A. Circuit Inspection B. Adding Fluid to the System C. Adjustments D. Lubrication E. Replacement Parts F. Product Life G. Troubleshooting VI. VII. Overhaul A. Service Tools B. Unit Removal C. Disassembly D. Cleaning E. Inspection, Repair and Replacement F. Assembly Service and Maintenance A. Start-Up B. Test
3 Section I Introduction A. Purpose of Manual. This manual describes the basic operating characteristics and provides service and overhaul information for Vickers 8/83 suffix single vane pumps. Information contained herein pertains to the latest design series. B. General Information. Related Publications Service parts information and installation dimensions are not contained in this manual. The installation drawings and parts catalogs listed in Table are available from Vickers. Model Codes Variations within each basic model series are covered in the model code. Table is a breakdown of the model codes covering these units. The model code will be stamped into the cover nameplate. If an older design unit is being updated to the new 8/83 design, stamp the new design number on the nameplate. Inquiries should always include the complete unit model code number as stamped on the nameplate. Model Parts Catalog Installation 5V I-358-S 5VT I-35-S 35V I-3-S 35VT I-39-S 560 5V I-359-S 5VT I-35-S Table. Related Publications Model Code Viton seals Omit if not required Pump series 5, 35, 5 Quiet intra-vane type pump Thru shaft connection mtg. (SAE bolt adapter flange) A A flange B B flange C C flange 5 SAE rated delivery USgpm 00 RPM at 00 PSI 5V 35V 5V USgpm 5 USgpm USgpm USgpm 30 USgpm 50 USgpm USgpm 35 USgpm 60 USgpm USgpm 38 USgpm 6 Port connections SAE Bolt Coupling For SAE A flange 30 involute spline w/.5 extension For SAE B flange 30 involute spline w/.5 extension For SAE C flange 30 involute spline w/.3 extension 8 Shaft type Straight key Splined 86 Straight key (heavy duty) Table. Model Code Breakdown 9 Port positions (Inlet cover positions viewed from cover end) A Opposite outlet port B 90 CW from outlet port C Inline with outline port D 90 CCW from outlet port 0 Design Rotation (Viewed from shaft end) L Left hand Omitted Right hand Industrial suffix 8 SAE bolt mounting 83 Foot mounted 3
4 Section II Description A. General 3. The single intra-vane pump with a 8/83 suffix is designed to operate at reduced noise levels, but still maintain the same reliability, operating characteristics, and service advantages of previous models. All sound reduction in the 8/83 series pump is accomplished within the cartridge kit. The ring, vanes, rotor and support plates have been redesigned. The pump housing remains unchanged. Thus, existing systems may be upgraded by simply replacing the cartridge kit. Figure shows the basic 8/83 cartridge kit. Note that vanes are assembled into the machined rotor slots. Previous designed models use 0 vanes. Figure. -8/-83 Basic Cartridge Kit Parts Section III Principles of Operation. A. General The operating principle of a vane pump is illustrated in Figure. A slotted rotor is splined to the drive shaft and turns inside a cam ring. Vanes are fitted to the rotor slots and follow the inner surface of the cam ring as the rotor turns. Centrifugal force and pressure under the vanes hold them out against the cam ring. Pumping chambers are formed between the vanes and the cam ring and are enclosed by the two support plates. to the small intra-vane area of the vane. As the pump vane rotates through the high and low quadrants, outlet pressure is alternately applied to the rest of the under vane area. This varying pressure under the vane reduces wear and increases pump efficiency. Pump delivery can be changed by changing the ring or installing a new cartridge kit. Table shows available delivery options. Cartridge kit part numbers are tabulated in the parts and service drawings (see Table.). The 8/83 series pumps are of a balanced intra-vane design (see Figure.). Outlet pressure is constantly applied System Pressure Rotation Outlet Outlet support plate feeds full load pressure to intra-vane area at all times. Inlet or Outlet Pressure Continuous Outlet Pressure High Pressure Quadrant Inlet Rotation Low Pressure Quadrant Holes in rotor segments feed load pressure under full vane area in pressure quadrant and inlet pressure under vane area in inlet quadrants. Figure. Vane Pump Operation
5 Section IV Installation and Operating Instructions A. Installation Drawings 5. The installation drawings listed in Table show operating characteristics, installation dimensions and port locations. B. Mounting and Drive Connections 6. CAUTION Pump shafts are designed to be installed in couplings with a slip fit. Pounding can injure the bearings. Shaft tolerances are shown on the installation drawings. (See Table.). Direct Mounting A pilot on the pump mounting flange (Figure 3) assures correct mounting and shaft alignment. Make sure the pilot is firmly seated in the accessory pad of the power source. Care should be exercised in tightening the mounting screws to prevent misalignment. Figure 3. Mounting Flange and Pilot Pilot Flange. Indirect Drive is not recommended for these pumps without Vickers engineering approval. C. Shaft Rotation. Pumps are assembled for either right hand (clockwise) or left hand (counterclockwise) shaft rotation as viewed from the shaft end. CAUTION Never drive a pump in the wrong direction of rotation. Seizure will result, necessitating expensive repairs. D. Piping and Tubing 8.. All pipes and tubing must be thoroughly cleaned before installation. Recommended methods of cleaning are sand blasting, wire brushing, pickling and power flushing with clean solvent to remove loose particles. NOTE For information on pickling, refer to 69.. To minimize flow resistance and the possibility of leakage, only as many fittings and connections as are necessary for proper installation should be used. 3. The number of bends in tubing should be kept to a minimum to prevent excessive turbulence and friction of oil flow. Tubing must not be bent too sharply. The recommended minimum radius for bends is three times the inside diameter of the tube. E. Hydraulic Fluid Recommendations 9. General Data Fluid in a hydraulic system performs the dual function of lubrication and transmission of power. It constitutes a vital factor in a hydraulic system, and careful selection of it should be made with the assistance of a reputable supplier. Proper selection of fluid assures satisfactory life and operation of system components with particular emphasis on hydraulic pumps. Any fluid selected for use with pumps is acceptable for use with valves or motors. Fluid recommendations noted in 69 are based on our experience in industry as a hydraulic component manufacturer. Where special considerations indicate a need to depart from the recommended fluids or operating conditions, see your Vickers sales engineer. Cleanliness Thorough precautions should always be observed to insure the hydraulic system is clean.. Clean (flush) entire new system to remove paint, metal chips, welding shot, etc.. Filter each change of fluid to prevent introduction of contaminants into the system. 3. Provide continuous filtration of fluid to remove sludge products of wear and corrosion generated during the life of the system.. Provide continuous protection of system from entry of filters, breathers, reservoirs, etc., cannot be over emphasized. 5. During usage, proper fluid filling and servicing of filters, breathers, reservoirs, etc., cannot be over emphasized. 6. Thorough precautions should be taken by proper system and reservoir design, to insure that aeration of the fluid will be kept to a minimum. 5
6 F. Sound Levels 0. Although system noise levels can be reduced by modifying pump design, fluid conditions also play a major part in reducing system noise levels. Some of the major factors affecting the fluid conditions that cause the loudest noises in a hydraulic system are:. Very high viscosities at start-up temperatures can cause pump noise due to cavitation.. Running with a moderately high viscosity fluid will impede the release of entrained air. The fluid will not be completely purged of such air in the time it remains in the reservoir before recycling through the system. 3. Aerated fluid can be caused by ingestion of air through the pipe joints of inlet lines, high velocity discharge lines, cylinder rod packings or by fluid discharging above the fluid level in the reservoir. Air in the fluid causes a noise similar to cavitation. G. Overload Protection. Relief valves limit pressure in the system to a prescribed maximum and protect components from excessive pressure. The setting of the relief valve depends on the work requirements of the system. H. Start-Up. With a minimum drive speed of 600 RPM, a pump should prime almost immediately if provision is made to initially purge the air from the system. Failure to prime within a reasonable time may result in damage due to lack of lubrication. The pump inlet line must be filled with fluid and must be tight and free from air leaks. It may be necessary to crack a fitting on the outlet side of the pump to purge air trapped in the system. Section V Service and Maintenance A. Circuit Inspection 3. Periodic inspection of the fluid condition and tube or pipe line connections can save time-consuming breakdowns and unnecessary parts replacement. The following should be checked regularly:. All hydraulic connections must be kept tight. A loose connection in a pressure line will permit the fluid to leak out. If the fluid level becomes so low as to uncover the inlet pipe opening in the reservoir, extensive damage to the pump can result. In suction or return lines, loose connections permit air to be drawn into the system resulting in noisy and/or erratic operation.. Clean fluid is the best insurance for long service life. Therefore, the reservoir should be checked periodically for dirt or other contaminants. If the fluid becomes contaminated, the system should be drained and the reservoir cleaned before new fluid is added. 3. Filter elements also should be checked and replaced periodically. A clogged filter element results in a higher pressure drop. This can force particles through the filter which would ordinarily be trapped, or can cause the by-pass to open, resulting in a partial or complete loss of filtration.. Air bubbles in the reservoir can ruin the pump and other components. If bubbles are seen, locate the source of the air and seal the leak. 5. A pump which is running excessively hot or noisy is a potential failure. Should a pump become noisy or overheated, the machine should be shut down immediately and the cause of improper operation corrected. B. Adding Fluid to the System. When hydraulic fluid is added to replenish the system, it should always be poured through a clean wire screen (00 mesh or finer) or preferably pumped through a 0 micron (absolute) filter. It is important that the fluid be clean and free of any substance which could cause improper operation or wear of the pump or other hydraulic units. Therefore, the use of cloth to strain the fluid should be avoided to prevent lint getting into the system. C. Adjustments 5. No periodic adjustments are required, other than to maintain proper shaft alignment with the driving medium. D. Lubrication 6. Internal lubrication is provided by the fluid in the system. Lubrication of the shaft coupling should be as specified by their manufacturers. Coat shaft splines with a dry lubricant (Molycoat or equivalent) to prevent wear. E. Replacement Parts. Reliable operation throughout the specified operating range is assured only if genuine Vickers parts are used. Sophisticated design processes and material are used in the manufacture of our parts. Substitutes may result in early failure. Part numbers are shown in the parts drawings listed in Table. Repair Kits Commonly replace parts usually provided in the form of a kit. (See Figure.) It is recommended that all such parts be replaced with the kit when a unit is overhauled. 6
7 CAUTION Individual cartridge parts are not interchangeable with similar parts of previous design models. Complete cartridge kits are interchangeable with previous designs. Rotor, vane and intra-vane assembled inside ring Inlet Support Plate Sealing Ring Back-up Ring and O-ring F. Product Life 8. The longevity of these products is dependent upon environment, duty cycle, operating parameters and system cleanliness. Since these parameters vary from application to application, the ultimate user must determine and establish the periodic maintenance required to maximize life and detect potential component failure. G. Troubleshooting 9. Table 3 lists the common difficulties experienced with vane pumps and hydraulic systems. It indicates probable causes and remedies for each of the troubles listed. Screw Bushing Outlet Support Plate Ring Location Pin Figure. Preassembled Cartridge Kit TROUBLE PROBABLE CAUSE REMEDY Excessive noise in pump. Low oil level in reservoir. Fill reservoir to proper level with recommended fluid. Air in system. Open reservoir cap and operate system until purged. Bleed hydraulic lines at highest point down stream of pump while system is under pressure. Vacuum condition. Check inlet (suction) line and fittings for air leaks. Oil too thick. Be certain correct type of oil is used in system. Warm up pump in cold weather until noise disappears. Damaged or missing pump seals at mating surfaces. Cartridge kit not assembled properly. Pump inlet/outlet lines reversed. Locate and replace damaged or missing seals. Reassemble cartridge kit. Replumb lines to proper port connections. Pump overheating. Internal leakage. If excessive internal leakage exists, return to shop for complete overhaul. Heat exchanger not functioning. Locate trouble and repair or replace. System not developing pressure. Relief valve open. Repair or replace. Loss of fluid internally (slippage). Return to shop for evaluation and repair. Cartridge kit not assembled properly. Reassemble kit. Cartridge kit assembled for opposite Reassemble kit to proper rotation. rotation. Pump inlet/outlet lines reversed. Replumb lines to proper port connnections. Disconnected or broken drive Locate and repair. mechanism. Loss of fluid. Ruptured hydraulic lines. Locate and repair. Leaking or missing seals. Locate and repair. Table 3. Troubleshooting Chart
8 Section VI Overhaul A. Service Tools 0. Standard Tools. One torque wrench with short extension and sockets. Select appropriate torque wrench according to cover screw specifications noted in Table.. One medium size screw driver. 3. One torque screw driver (5 lb. in. maximum).. One internal retaining ring pliers. 5. Hydraulic oil lubricant or equivalent (SAE 0W motor oil). NOTE In addition to the above tools, an arbor press may be required to service the shaft bearing. A small ball peen hammer and a center punch may also be helpful during removal of the shaft key. Special Tools A shaft seal driver (Figure 5) is the only special tool required for overhaul. B. Unit Removal WARNING Turn off all electrical power and relieve hydraulic pressure. Lower all vertical cylinders. Block any load whose movement could generate pressure.. Close off hydraulic oil source to pump inlet if an overhead reservoir is used.. Remove the unit from the system. 3. Cap all system and unit openings to prevent entry of dirt or moisture. C. Disassembly The index numbers on Figure 8 are in order of the disassembly sequence.. Thoroughly clean pump exterior. C B. Use a prick punch and mark the position of cover () with respect to the body (9). Mark position of the flange with respect to cover on VT models. D A 3. Remove the two screws () and remove the mounting flange from the pump.. Remove the key () from the shaft (6). NOTE 0.5 /6 5 Break sharp edges and polish The following step (5) pertains to 5VT, 35VT or 5VT thru-shaft models only. Refer to Figure Disassemble (VT) thru-shaft parts as follows: a. Remove four screws (5) from adapter flange (6). Remove the adapter flange from inlet cover (). E b. Remove and discard O rings () from both sides of adapter flange c. Remove spline coupling (8) from end of shaft (0). Do not remove retaining ring (9) from coupling. Note: All Dimensions are in inches Model 5V 35V 5V A B Figure 5. Shaft Seal Driver Dimensions C D E d. Remove four screws (0) from inlet cover (). Remove the inlet cover from body (9). 6.Remove the four screws (3) from cover () and remove cover (*5V models only)..remove cartridge kit () from shaft (6). 8.Remove seals ( through 5) from cartridge kit (). Proceed to disassemble cartridge kit () according to number sequence. 9.Pry under one coil and remove the spirolox ring (3) out of the body (9). See Figure 6. 8
9 Spirolox Ring (3) c. Inspect bushing for wear and scoring. Wear on one side indicates that the pump and drive motor were not aligned. See Figure.. Check bearing (5) for wear, looseness and pitted or cracked races. Figure 6. Removing Spirolox Ring Hooked Tool 0. Pull the shaft group ( through 6) from the body (9). If the bearing (5) or shaft (6) needs replacement, remove retaining ring () and press the bearing off the shaft with an arbor press. Apply pressure to the inner race of the bearing during removal.. Remove washer () from body.. Drive the shaft seal (8) out of body (9). D. Cleaning. All parts must be thoroughly cleaned and kept clean during inspection and assembly. Contamination in the unit will cause excessive wear, leakage and decreased service life. Use a commercial solvent which is compatible with the system fluid. Thoroughly clean all parts. Drying parts with compressed air after cleaning is not recommended unless the air is completely filtered to remove water and contamination. E. Inspection, Repair & Replacement Check that all internal passages are clean and unobstructed. Examine all mating surfaces for nicks and burrs. Check locating pins and holes for wear and burrs. Check the condition of threaded parts and threaded holes. Check all retaining ring recesses. Minor burrs can be removed with an India stone. Replace any part that shows wear or damage. The following parts are subject to special attention.. Cartridge Kit (). In order to obtain maximum overhaul life of the pump, a complete cartridge kit should be installed if wear or scoring is noticed during the following steps. a. Inspect the mating surfaces of the rotor (0), outlet support plate () and inlet support plate (). b. Inspect the vanes and intra-vanes () for burrs, wear and play in the rotor (0) slots. The intra-vanes should not bind in the vanes. Remove minor burrs with an India stone. 3. Inspect the seal and bushing mating surfaces on shaft (6) for scoring and wear. Replace the shaft if marks cannot be removed by light polishing. F. Assembly Refer to parts and service drawing listed in Table for replacement parts. Always replace old seals with new seals when overhauling a unit. If a cartridge kit needs replacing, new seals are included in the cartridge kit. Apply a light film of hydraulic fluid to all component parts to facilitate assembly and provide initial lubrication. Install parts in reverse order of disassembly. See Figure 8.. Install shaft seal (8) into body (9) so that the spring in the seal faces the inside of the pump. Press the shaft seal into the body. Use shaft seal tool shown in Figure 5 and an arbor press.. Install washer () into body. 3. If required, press bearing (5) on to shaft (6) and secure with retaining ring ().. Recheck shaft key way for nicks and burrs that could cut the shaft seal. Remove burrs. Thoroughly lubricate the key way end of shaft and shaft seal lip with hydraulic oil. Carefully install shaft group (items through 6) through the seal and into body (9). Spread the spirolox ring (3) and feed it into the groove located behind the bearing. This will secure the shaft group within body (9). 5. Assembly sealing ring () into body (9). 6. If a new cartridge kit is required, install new cartridge kit () on the shaft and into the body (9). If cartridge kit assembly is required, assemble in the reverse order of disassembly. During assembly, note the following precautions; a. Make sure the rotation arrows on ring (9) and rotor (0) point in the direction of rotation. b. Be certain the sharp edges of vanes () lead in direction of pump rotation. See Figure. c. Make sure O ring () and back-up ring (3) are positioned correctly as shown on Figure 8.. Apply a small amount of hydraulic fluid on threads of two screws (6). Thread the screws into cartridge kit. Install cartridge kit () on the shaft and into body (9). 9
10 Rotor Inlet Direction of rotation a. Line up the two cartridge kit pins (8) with the holes in inlet cover b. Install spline coupling (8) on end of shaft (6). NOTE If a new shaft and coupling kit is required, install retaining ring (9) into coupling (8) prior to coupling installation. c. Install O rings () on both sides of adapter flange (6). Sharp edges lead direction of rotation Figure. Positioning Vanes in Rotor Vane Ring 8. Install O ring (5) over the cartridge kit () and into the body O ring groove. 9. Line up the two cartridge pins (8) with the holes in cover (). Assemble cover () over cartridge kit and up against body face. Position cover () according to markings made during step C- of the disassembly procedure. Secure the cover with four screws (3). Torque screws (3) to specifications noted in Table. Screw (3) Torque Specifications (Figure 8) Model N.m lb. ft. 5V V V Screw (0) (Figure 8) 5VT VT VT d. Connect adapter flange (6) to inlet cover () with four screws (5). (NOTE: Lockwashers are used with screw (5) for C adapter flanges only.) Torque screws (5) to specifications noted in Table 5. Screw (5) Torque Specifications Model Adapter Flange N.m lb. ft. 5VT 35VT A or B VT 35VT 5VT C Table 5. Screw (5) Torque Specifications. Install key () on shaft (6).. Place pump into mounting bracket () and secure it with the two mounting bracket screws. Table. Torque Specifications for Screw (3)/(0) Section VII Start-Up and Test A. Start-Up. Install the unit into the system. Make sure the drive shaft is aligned properly. Be sure all connections are tight and the hydraulic fluid source is open to pump inlet before start-up. The pump should prime almost immediately with a minimum drive speed of 600 RPM. Intermittently operate (jog) the pump until it primes. It may be necessary to loosen the outlet fitting temporarily to purge trapped air. Failure of the pump to prime in a short period of time indicates incorrect assembly or restricted flow from the reservoir. B. Test Use your hydraulic system to test the unit. Refer to the installation drawings listed in Table for recommended speeds and pressures. If more precise testing is desired, consult your Vickers sales engineering office. 0
11 5 6 A **VT (Thru Shaft Models) 5 6 B 6 C Item Nomenclature Qty Foot Bracket Kit Key Screw Cover Screw Adapter Flange O Ring Spline Coupling Retaining Ring Screw Cartridge Kit (items -) Back-up Ring O Ring Sealing Ring O Ring A/R Item Nomenclature Qty Screw Inlet Support Plate Pin Ring Rotor Vanes & Intra-Vanes Outlet Support Plate Spirolox Ring Retaining Ring Bearing Shaft Washer Shaft Seal Body Figure 8. Exploded Parts Breakdown
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