Overhaul Manual Vickers Vane Pumps Small and Large Series Combination Pumps VC(K)(S)-**-(*)*D*-6(1) VC(K)(S)-**-(*)-*-*D*-5(1) Revised 12/1/86 I-3150-S
Table of Contents Section I. Introduction................................................................................ 3 A. Reference Material....................................................................... 3 Table 1. Reference Material............................................................................ 3 B. Different Model Sheets.................................................................... 3 C. Kits................................................................................... 3 D. Model Number........................................................................... 3 Page II. Overhaul.................................................................................. 4 A. Unit Removal............................................................................ 4 B. Special Tools............................................................................ 4 C. Improvised Tools......................................................................... 4 D. Disassembly............................................................................ 4 Figure 1. Disassembly Sequence - Relief Valve Sub-Assy................................................... 4 Figure 2. Disassembly Sequence - Relief and/or Unloading valve Sub-Assy..................................... 5 E. Cleaning............................................................................... 5 F. Inspection Repair and Replacement.......................................................... 5 Figure 3. Disassembly Sequence - Relief and Unloading Valve Sub-Assy........................................ 6 Figure 4. Disassembly Sequence - Relief and Unloading Valve Sub-Assy....................................... 7 G. Assembly............................................................................... 7 Figure 5. Legend................................................................................... 10 Figure 6. Positioning Vanes and Rotor................................................................... 10 Figure 7. Disassembly Sequence - Lower Cover Sub-Assy.................................................. 11 H. Unit Installation.......................................................................... 11 III. Start-up and Test............................................................................ 12 A. Start-up................................................................................ 12 B. Test................................................................................... 15 Eaton Hydraulics, Incorporated 2000 All Rights Reserved 2
Section I Introduction A. Reference Material Installation dimensions, operating specifications, and part numbers are not contained in this manual. Refer to the appropriate installation and parts drawings listed in Table 1 for this information. Model VC(K)(S)-108 VC(K)(S)-109 VC(K)(S)-110 VC(K)(S)-29 VC(K)(S)-39(*) VC(K)(S)-49 VC(K)(S)-128 VC(K)(S)-129 VC(K)(S)-138(*) VC(K)(S)-139(*) VC(K)(S)-148 VC(K)(S)-149 Installation Drawing I-133570 for combination 3 I-133571 for combination 6 I-213579 for combination 33 I-133568 for combination 3 I-133569 for combination 6 I-213580 for combination 33 Table 1. Reference Material Parts Drawing I-3152-S I-3156-S B. Different Model Sheets Sections I, II, and III of this overhaul manual contain instructions for the models listed on the front page. If the model number of your unit is not exactly as those shown, you may have an earlier or later design unit. Supplemental information, if needed, will appear in section IV (different model sheet). If there is no section IV, use the information contained in sections, I, II, and III. C. Kits Gasket kits and cartridge kits are available for these pumps. Refer to the applicable parts drawings listed in Table 1. It is recommended that all such parts be replaced with the kit when a unit is overhauled. If the first two symbols of the model number on your pump are F1 or F3 it means that a different gasket kit is required. Refer to seal manual I-4000-S for the part number of this kit. D. Model Number If you have an early design unit and you replace old parts with the improved parts of a later design unit, stamp the new design number on the nameplate. Refer to the appropriate parts drawing listed in Table 1 for an explanation of the model number. 3
Section II Overhaul A. Unit Removal WARNING Turn off all electrical power and relieve hydraulic pressure. Lower all vertical cylinders. Block any load that could generate pressure. 1. Remove the unit from the system. 2. Cap all system and unit openings to prevent entry of dirt or moisture. B. Special Tools A torque wrench should be available for tightening head screws. Two 0-1000 psi gauges will be needed to adjust the valves after overhaul. C. Improvised Tools No improvised tools are required for overhaul of the unit. D. Disassembly The index umbers on Figure 5 are in order of the disassembly sequence. 1. Thoroughly clean the exterior of the pump. 2. Remove the eight screws (1, Figure 5), eight washers (2), and flange (3A) or foot (3B) mount. 3. Remove the key (4). 4. Remove the eight screws (5) and adapter (6). 5. Pull the shaft group (9) from the unit. Remove the snap ring (10). Use an arbor press to remove the bearing (11) from the shaft (12). 6. Remove the packing (13). 7. Remove the eight screws (14), head (15), and packing (16). 8. Pull cartridge group (17) from the unit. Disassemble the group according to the number sequence. 9. Remove the eight screws (24), head (25), and packing (26). If the bearing (27) remains in the head (25), a light tapping will usually remove it. In rare instance it may be necessary to insert an expandable tool into the bearing and pull it out. 10. Pull cartridge group (28) from the shaft and disassemble according to the number sequence. VCS, VCKS units only 16A 16B VC, VCK units only 11 10 6 2 5 1 4 3 14 15 Housing is slightly different for Pressure 2 Valve on Combination 6 Units 17 13 12 9 8 7 Item 1 Group (Items 2-6) 1 2 Nut 1 3 Screw 1 4 Plate 1 5 Knob 1 6 Adjusting Screw 1 7 Retainer 1 8 Plunger 1 9 O-Ring 1 Item 10 Spacer 1 11 O-Ring 1 12 Spring 1 13 Piston 1 14 Plug 1 15 Seat 1 16A Plug and O-Ring 1 (on applicable models) 16B Plug 1 (on applicable models) 17 Cover 1 Figure 1. Disassembly Sequence - Relief Valve Sub-Assy. 4
VCS, VCKS only 4B 1 2 6 VC, VCK only 4A 3 4 Item 1 Adjusting Screw 1 2 Lock Nut 1 3 Retainer 1 4 O-Ring 1 5A Plug 1 (on applicable models) 5B Plug and O-Ring 1 (on applicable models) 6 Cover 1 Figure 2. Disassembly Sequence - Relief and/or Unloading valve Sub-Assy. NOTE Note or mark the position of the subassemblies 35A, 35B, and 35E before removing them. 11. Remove the eight screws. gasket or gaskets, and appropriate relief and/or unloading valve subassemblies (35A), (35B), (35C), (35D), and (35E). Disassembly of these items is shown in the referenced figure. 12. Remove spring (36) and spool (37). 13. Remove spring or springs (38) and piston (39). 14. Remove the eight screws (40), lower cover subassembly (41), and gasket (42). Disassembly of the lower cover subassembly is shown in figure 7. NOTE The seat (45) rarely needs replacement and therefore should not be removed unless it is obviously damaged. An expandable tool, threading, or a similar method must be employed to grip the insdie diameter fo the seat when it is necessary to pull it out. 15. Remove the plug (43). Remove the poppet and spring (44A). If your unit contains the plug (44B) instead of the poppet and spring, do not remove it. The only reason to remove the plug (44B) would be to convert the unit to a different combination. 16. Remove parts (46) thru (50). NOTE The seat (51) rarely need replacement and therefore should not be removed unless it is obviously damaged. When it is necessary to remove it, use a brass rod with a diameter slightly less than the seat diameter and drive the seat out through the bottom of the housing (52). E. 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 any part after it is lapped. Drying parts with compressed air after cleaning is not recommended unless the air is completely filtered to remove water and contamination. F. Inspection, Repair, and 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 snap ring recesses. Minor burrs can be removed with an India stone. Replace any part which shows excessive wear or damage. The following parts are subject to special attention: 1. Bearings (11) and (27). Check the bearings for wear, burning, and pitted or cracked races. Inspect the larger bearing (11) thoroughly. 2. Shaft (12). Inspect the shaft (12) for scoring at the seal (7) mating surface. Remove minor damage by polishing. A rough surface will damage a new seal. This damage does not cause oil leakage when this type of pump is operating (assuming a standard or non-flooded inlet installation). Aeration of the fluid will occur instead which is apparent by noisy operation. 5
16 17 19 20 21 22 25 24 23 4 3 18 5 2 12 13 14 15 10 11 1 9 8 7 6 Item 1 Cover 2 Tube 1 3 O-Ring 1 4 O-Ring 1 5 Cover 1 6 Plug 1 7 O-Ring 1 8 Spring 1 9 Piston 1 10 Group (Items 11-15) 11 Nut 1 12 Screw 1 13 Plate 1 Item 14 Knob 1 15 Adjusting Screw 1 16 Retainer 1 17 Plunger 1 18 O-Ring 1 19 Spacer 1 20 O-Ring 1 21 Spring 1 22 Piston 1 23 Plug 1 24 Seat 1 25 Plug 1 Figure 3. Disassembly Sequence - Relief and Unloading Valve Sub-Assy. 3. Cartridge Group (17). In order to obtain maximum overhaul life of the pump, a complete cartridge kit should be installed if excessive wear or scoring is noticed during the following steps. a. Inspect the mating surfaces of the rotor (20) and bushings (18 and 22). Place the bushings on the rotor and check for excessive wear between the rotor hubs and bushing hubs. Remove minor damage by lapping. The surfaces of the bushings must not be made convex during lapping. Any tendency to rock the bushing during lapping must be avoided. Check for flatness after lapping. b. Inspect the vanes (19) and rotor slots for burrs and wear. Remove minor burrs with an India stone. A new rotor and vane set should also be checked and stoned as a precaution. Nicks and burrs can be incurred during handling. A lubricated vane should move freely in the rotor slot. c. Inspect the inside contour of the ring (21) for scoring and wear. 4. Cartridge Group (28). This cartridge group should also be replace if excessive wear or scoring is noticed during inspection. a. Inspect the mating surfaces of the rotor (31) and bushings (29 and 33). Place the bushings on the rotor and check for excessive wear between the rotor hubs and bushing hubs. Remove minor damage by lapping. The flat surfaces of the bushings must not be made convex during lapping. Any tendency to rock the bushing during lapping must be avoided. Check for flatness after lapping. b. Inspect the vanes (30) and rotor slots for burrs and wear. Remove minor burrs with an India stone. A new rotor and vane set should also be checked and stones as a precaution. Nicks and burrs can be incurred during handling. A lubricated vane should move freely in the rotor slot. c. Inspect the inside contour of the ring (32) for scoring and wear. 5. Spool (37). Inspect for scoring and wear. 6. Piston (39). Inspect for scoring and wear. 7. Springs (36 and 38). Inspect for distortion. 8. Housing (52). Inspect all bores for scoring and wear. 9. Relief Valve Subassembly (Figure 1). a. Inspect for scoring and wear of the plunger (8), spacer (10), piston (13), and seat (15). b. Inspect for distortion of the spring (12). 6
7 8 10 11 12 13 20 15 14 9 21 19 18 17 16 3 4 5 6 1 2 Item 1 Group (Items 2-6) 2 Nut 1 3 Screw 1 4 Plate 1 5 Knob 1 6 Adjusting Screw 1 7 Retainer 1 8 Plunger 1 9 O-Ring 1 10 Spacer 1 11 O-Ring 1 Item Figure 4. Disassembly Sequence - Relief and Unloading Valve Sub-Assy. 12 Spring 1 13 Piston 1 14 Plug 1 15 Seat 1 16 Plug 1 17 O-Ring 1 18 Spring 1 19 Piston 1 20 Plug 1 21 Cover 1 10. Relief and/or Unloading Valve Subassembly (Figure 2). Inspect the retainer (3) for scoring and wear. 11. Relief and Unloading Valve Subassembly (Figure 3). a. Inspect the piston (9), plunger (17), spacer (19), piston (22), and seat (24) for scoring and wear. b. Inspect springs (8 and 21) for distortion. 12. Relief and Unloading Valve Subassembly (Figure 4). a. Inspect the plunger (8), spacer (10), piston (13), seat (15), and piston (19) for scoring and wear. b. Inspect springs (12 and 18) for distortion. G. Assembly Replace all of the packing, gaskets, O-Rings, and the seal with those supplied in the gasket kit. Apply a light film of clean system fluid to the parts prior to installing them. This will make assembly easier and provide initial lubrication. The parts are assembled in the reverse order of disassembly and according to the following procedure steps. 1. Using an arbor press install the seat (51, Figure 5) if it has been removed. Make certain that the relieved side of the seat faces the tank porting. 2. Install parts (50) thru (46). 3. Using an arbor press, install seat (45) if it has been removed. 4. Install parts (44A) and (43). 5. Assemble the lower cover subassembly (41) in the reverse order of the number sequence in Figure 7. 6. Install parts (42, Figure 5) thru (36). 7. Assemble the appropriate valve subassemblies (35A, Figure 1), (35B, Figure 2), (35C, Figure 3), (35D, Figure 4), and (35E, Figure 1) in the reverse order of the number sequence. 8. Install subassemblies (35A), (35B), (35C), (35D), and (35E) as shown in Figure 5. Position them according to the note or mark made during disassembly. 9. Assemble cartridge group (28). Make certain that any arrows on the ring (32), bushings (29) and (33), and rotor (31) are all pointing in the same direction. In addition, the sharp edges of the vanes (30) must lead the direction of rotation. (See figure 6). 10. Orient and install the cartridge group (28, Figure 5) in the housing (52) according to the direction of drive shaft rotation required (observe arrows on cartridge group). Make certain that the locating pin (34) lines up with the hole in the housing. 11. Install bearing (27) in the head (25). 12. Install packing (26). 13. Align the locating pin (34) in the cartridge group with the locating hole in the head (25) and install the head. Screw the eight screws (24) finger tight and then alternately tighten them to 50 inch pounds torque. Temporarily insert the shaft (12) and rotate it. If rotation is completely free, continue the alternate tightening of the screws until a slight drag is felt. If the shaft cannot be rotated, remove the cartridge group and determine the cause of binding. 7
Combination 6 Only See Figure 1 35A Combinations 3, 9, 13, 16, 23, or 26 See Figure 2 35B Flange Mounted Units Only 1 2 3A Flange Mounted Units Only 8 7 4 14 5 3B Foot Mounted Units Only 6 12 9 11 10 13 15 16 18 17 8
Large Series, Combinations 33, and 43 See Figure 3 35C Small Series, Combinations 33, and 43 See Figure 4 35D Combinations 3, 6, 9, 13, 16, 23, or 26 See Figure 1 35E 36 38 37 39 28 52 29 31 32 34 33 26 27 25 20 19 21 23 22 17 VCS, VCKS 49 Combinations 3, 13, 33, 43 47 51 46 30 24 Combinations 48 3, 13, 33, or 43 42 45 43 Combinations 50 3, 13, 33, or 43 44B Combinations 6, and 16 44A Combinations 3, 9, 13, 23, 26, 33 or 43 See Figure 7 41 40 9
Item 1 Screw 8 2 Lockwasher 8 (on applicable models) 3A Flange Mount 1 (on applicable models) 3B Foot Mount 1 (on applicable models) 4 Key 1 5 Screw 8 6 Adapter 1 7 Seal 1 8 Gasket 1 9 Shaft Group (Items 10-12) 1 10 Snap Ring 1 11 Bearing 1 12 Shaft 1 13 Packing 1 14 Screw 8 15 Head 1 16 Packing 1 17 Cartridge Group (Items 18-23) 18 Bushing 1 19 Vane 12 20 Rotor 1 21 Ring 1 22 Bushing 1 23 Pin 1 24 Screw 8 25 Head 1 26 Packing 1 27 Bearing 1 28 Cartridge Group (Items 29-34) 29 Bushing 1 30 Vane 12 31 Rotor 1 Item 32 Ring 1 33 Bushing 1 34 Pin 1 35A Relief Valve SubAssy 1 (on applicable models) 35B Relief and/or Unloading 1 (on applicable models) Valve SubAssy 35C Relief and Unloading 1 (on applicable models) Valve SubAssy 35D Relief and Unloading 1 (on applicable models) Valve SubAssy 35E Relief Valve 1 (on applicable models) 36 Spring 1 37 Spool 1 38 Spring or Springs 1 or 2 (depending on model) 39 Piston 1 40 Screw 8 41 Lower Cover Subassy 1 42 Gasket 1 43 Plug 1 44A Poppet and Spring 1 (on applicable models) 44B Plug 1 (on applicable models) 45 Seat 1 46 Plug 1 47 Plug 1 48 Reducing Bushing 1 (on applicable models) 49 O-Ring 1 (on applicable models) 50 Plug 1 (on applicable models) 51 Seat 1 52 Housing 1 14. Assemble cartridge group (17). Make certain that any arrows on the ring (21), bushings (18 and 22), and rotor (20) are all pointing in the same direction. In addition, the sharp edges of the vanes (19) must lead the direction of rotation. (See Figure 6.) 15. Orient and install the cartridge group (17, Figure 5) in the housing (52) according to the direction of rotation (observe arrows) established by cartridge group (28). Make certain that the locating pin (23) lines up wit the locating hole in the housing (52). 16. Install packing (16). 17. Align the locating pin (23) in the cartridge group with the locating hole in the head (15) and install the head. Alternately tighten the screws (14) to 50 inch pounds torque for a small series pump or 150 inch pounds torque for a large series pump. Temporarily insert the drive shaft (12) deep enough to engage only cartridge group (17) and rotate it. If rotation is completely free, continue the alternate tightening of the screws until a slight drag is felt. If the shaft cannot be rotated, remove the cartridge group and determine the cause of binding. Figure 5. Legend Sharp Edges Lead Direction of Rotation Right Hand Rotation Shown (Viewed from Drive Shaft End) Figure 6. Positioning Vanes and Rotor Vane Rotor Ring Pin 10
Combinations 3, 13, 23, 26, 33 or 43 Models with Maximum Pressure Code A, B, OR D (in model code number) 2 6 5 1 Small Series, Combination 43 6 Design only VCS, VCKS Units only 8 10 4A Combinations 6, 9, 16, 23, or Large Series Combination 43, or Small Series Combination 43 of -61 Design 9 VC, VCK Units only 7 4B Large Series, Combination 33 (This is an Orifice Plug, IE... It has a hole through the center) 3 Item 1 Ball 1 (on applicable models) 2 Plunger 1 (on applicable models) 3 Plug 1 4A Plug 1 (on applicable models) 4B Orifice Plug 1 (on applicable models) 5 Plug 1 6 Plug 1 (on applicable models) 7 Plug 1 (on applicable models) 8 Plug and O-Ring 1 (on applicable models) 9 Plug 1 10 Cover 1 Figure 7. Disassembly Sequence - Lower Cover Sub-Assy. 18. Install the bearing (11) on the shaft (12). Install snap ring (10). Check the keyway end of the shaft again to be certain it is free of burrs. 19. Install packing (13). 20. Install the shaft group (9). 21. Install the gasket (8) and seal (7) in the adapter (6). The solid (closed) edge of the seal must be seated against the gasket and bottom of the counterbore. Use an arbor press with a ram or adapter diameter slightly less than the seal diameter to prevent damage to the seal. 22. Thoroughly grease the lip of the seal after it is seated. Grease the keyway end of the drive shaft and carefully install the adapter plate (6) so that the seal is not damaged. Secure with eight screws (5). 23. Install parts (4) thru (1). H. Unit Installation Install the unit in the system making sure that all connections are tight. 11
Section III Start-up and Test CAUTION The precautions and procedures for inital start-up are extremely important. Incorrect start-up may cause seizure of the pump. A. Start-up The start-up procedures for the nine different combinations are given. In some instances, the procedures may not be the easiest for a specific system installation. If for example you have a 16 combination pump, it may be easier to control the auxiliary pilot pressure by valving in your system instead of removing the line. Certainly then, you should use the easier method. The only purpose in the manipulation of the lines and plugs is to make certain that both pump cartridges are started under pressure and stay under pressure during initial start-up. This pressure will force fluid through the inside of the pump to provide lubrication. 1. Combination 3 Pumps. Schematic of Type 3 Combination a. Adjust the relief valve (35E, Figure 5) to approximately the center of the adjustment range. b. Adjust the unloading valve (35B) to maximum pressure (all the way in). NOTE A nominal pressure for initial start-up would be approximately 500 psi. If the electric drive motor in your system is not large enough to maintain 500 psi on both pump cartridges, reduce the valve setting for pressures of approximately 300 psi. c. Remove the plugs and install a pressure gauge in the reducing bushing (48, figure 5) and another one in the top of the relief valve (35E). d. Block the machine travel or otherwise restrict the pump delivery so that pressure will build up to the relief valve setting. e. Intermittently operate (jog) the pump until it primes. It may be necessary to temporarily loosen a fitting to purge trapped air. If the pump does not prime within a very short period of time, shut it down and determine the cause. Restricted flow from the reservoir, incorrect rotation, or improper assembly may be the cause. f. Continue to operate the pump under pressure as the heat slowly builds up to operating temperature. This may take 5 minutes or more. When the pump is at operating temperature, let it run for approximately 20 minutes and continually check it for excessive heat. g. Shut the pump down and remove the machine block or open the pump delivery path. h. Turn the relief valve out to minimum pressure adjustment. i. Start the pump and increase the setting of the relief valve until the minimum pressure required to move the work load smoothly is obtained. Note this pressure reading. j. Cycle the work load to the end of its travel or block the load. k. Turn the relief valve out to minimum pressure adjustment. l. Adjust the unloading valve (35B) to approximately the center of the adjustment range. m. Slowly increase the setting of the relief valve while watching the unloading pressure gauge (in bushing). The gauge will drop to zero when the unloading valve setting is reached. Note the pressure at which this happens and compare it with minimum pressure required to move the work load. If it is below the work load requirement, increase the setting of the unloading valve. If above, decrease the setting of the unloading valve. n. Turn the relief valve out to minimum and slowly increase it again until the unloading valve gauge drops to zero. Compare the pressure to work load requirement. Increase or decrease the unloading valve setting as required. o. Repeat the procedure until the unloading pressure is approximately 50 psi above work load requirement. p. Lock the unloading valve setting. q. Adjust the relief valve for the maximum system pressure requirement. This pressure must be at least 150 psi above the unloading valve setting. Lock the setting. r. Shut the system down, remove the gauges, and replace the plugs. 12
2. Combination 6 Pumps. Schematic of Type 6 Combination PR2 a. Adjust both relief valves (35A, Figure 5) and (35E, Figure 5) to the center of the adjustment range. NOTE A nominal pressure for initial start-up would be approximately 500 psi. If the electric drive motor in your system is not large enough to maintain 500 psi on both pump cartridges, reduce the valve setting for pressures of approximately 300 psi. b. Remove the plugs from the top of the relief valves and install pressure gauges. c. Block both outlet ports or otherwise restrict pump delivery so that pressure will build up to the relief valve settings. d. Intermittently operate (jog) the pump until it primes. It may be necessary to temporarily loosen a fitting to purge trapped air. If the pump does not prime within a very short period of time, shut it down and determine the cause. Restricted flow from the reservoir, incorrect rotation, or improper assembly may be the cause. e. Continue to operate the pump under pressure as the heat slowly builds up to operating temperature. This may take 5 minutes or more. When the pump is at operating temperature, let it run for approximately 20 minutes and continually check it for excessive heat. f. Adjust the relief valves to the maximum pressure requirement for each outlet. Lock the adjustment. g. Shut the system down, remove the gauges, and replace the plugs. h. Remove the machine blocks or open the pump delivery paths. 3. Combination 9 Pumps. Use the same procedure as used for the combination 6 pumps with the following exceptions: PR2 a. The valves to be adjusted are (35B, Figure 5) and (35E, Figure 5). b. The pressure gauge for setting relief valve (35B) cannot be installed in the cover. Install the gauge in the pressure 2 line or a comparable location if available. 4. Combination 13 Pumps. Use the same procedure as used for the combination 3 pumps with the following exceptions: a. Disconnect the auxiliary pilot pressure line for the unloading valve (35B) at the source. Plug the source outlet and use a clean container to collect leakage fluid which will flow from the open end of the line. b. Remove the pilot source outlet plug and connect the pilot line after initial start-up and adjustments are complete. Schematic of Type 13 Combination PILOT PRESS. 5. Combination 16 Pumps. Use the same procedure as used for the combination 6 pump with the following exceptions: Schematic of Type 16 Combination PILOT PRESS. PR2 a. The valves to be adjusted are (35B, Figure 5) and (35E, Figure 5). b. The pressure gauge for setting valve (35B) cannot be installed in cover. Install the gauge in the pressure 2 line or a comparable location if available. c. Disconnect the pilot pressure line both at the source and at the lower cover (41) of the pump. Plug both openings. d. Remove the pilot pressure plugs and connect the pilot line after initial start-up and adjustments are complete. 6. Combination 23 Pumps. Use the same procedure as used for combination 6 pumps with the following exceptions: Schematic of Type 9 Combination 13
PILOT PRESS. MAN. Schematic of Type 23 Combination PR2 a. The valves to be adjusted are (35B, Figure 5) and (35E, Figure 5). b. The pressure gauge for setting valve (35B) cannot be installed in the cover. Install the gauge in the pressure 2 line or a comparable location if available. c. Disconnect the pilot pressure line from the source and also from the lower cover (41) of the pump. Plug both the source and pump openings. d. Remove plug (6, Figure 7) from the lower cover of the pump. Replace plug (5). e. After initial start-up and adjustment are complete, connect the pilot pressure line after removing the plugs. Replace plug (6, Figure 7). 7. Combination 26 pumps. Use the same procedure as used for combination 3 pumps with the following exceptions: PILOT PRESS. PR2 Schematic of Type 26 Combination a. Both the pressure 1 and pressure 2 outlets must be blocked. b. Disconnect the pilot pressure line both at the source and at the lower cover (41) of the pump. Plug both openings. c. After initial start-up and adjustments are complete, remove the plugs and connect the pilot pressure line. 8. Combination 33 & 43 Pumps. Schematic of Type 33 Combination Schematic of Type 43 Combination MAN. a. Adjust valve (35C, Figure 5) or (35D, Figure 5) approximately one-third of the maximum adjustment onethird of the maximum adjustment (one-third in from full out position). b. Remove plug (6, Figure 7) from the lower cover. c. If combination 43 pump is being started, disconnect the pilot pressure line both at the source and at the lower cover of the pump. Plug both openings. d. If a combination 33 pump is being started, install a plug (4A, Figure 7) in the lower cover. The orifice plug (4B) must be removed first if the pump is a large series combination 33. e. Remove plug (46, Figure 5) and install a pressure gauge to check the maximum relief pressure. f. Remove plug (25, Figure 3) or (20, Figure 4) and install a pressure gauge to check unloading pressure. 14
NOTE A nominal pressure for initial start-up would be approximately 650 psi (gauge in housing).the unloading pressure gauge would then read approximately 375 psi because of the fixed differential in the 33 and 43 design. If the drive motor in your system is not large enough to maintain these pressures, reduce the valve setting to approximately 500 psi maximum pressure (225 psi on unloading gauge). g. Block both outlet ports or otherwise restrict pump delivery so that the pressures will build up to the valve setting. h. Intermittently operate (jog) the pump until it primes. It may be necessary to temporarily loosen a fitting to purge trapped air. If the pump does not prime within a very short period of time, shut it down and determine the cause. Restricted flow from the reservoir, incorrect rotation, or improper assembly may be the cause. i. Continue to operate the pump under pressure as the heat slowly builds up to operating temperature. This may take 5 minutes or more. When the pump is at operating temperature, let it run for approximately 20 minutes and continually check it for excessive heat. j. Adjust the relief valve for the maximum system pressure (gauge in housing). Lock the setting. k. Shut the system down, remove the gauges, and replace the plugs. l. Remove the plug (4A, Figure 7). Replace orifice plug (4B, Figure 7) if your pump is a large series combination 33. m. Remove the plugs and connect the pilot pressure line if your pump is a combination 43. B. Test n. Replace plug (6, Figure 7). The optimum performance of the pump in your system is a sufficient test. If a more rigorous test is desired, consult your Vickers Industrial District Sales Office for test stand requirements and construction. 15