Bosch VPV 16 Installations- und Betriebsanleitung

Hydraulics

VPV Vane Pump

Whisper™ Pump

Service and Repair Guide

Courtesy of CMA/Flodyne/Hydradyne ▪Motion Control ▪Hydraulic ▪Pneumatic ▪Electrical ▪Mechanical ▪(800) 426-5480 ▪www.cmafh.com

Welcome to the Service Guide for the VPV Pump !

Dear Customer:

First of all we would like to thank you for choosing the Bosch VPV Pump.

This brochure was designed as a guide covering all aspects of the repair procedures and to help

accomplishmaximumperformanceandalonglifefortheBoschVPV16cc–164cc(1in3–10in3),

210 bar (3000 PSI) pump.

On the following pages there is an illustrated step by step guide for all repair procedures.

If there are any additional questions our technical support team will be glad to help. Please call:

Phone: (262)554-7100or

Fax: (262)554-7117

If you have Internet access we would like to invite you to visit our Website:

http://www.boschat.com

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Service and Repair Guide 1

Section 1: Pump

1.1 DisassemblyProcedures–VPV16–164

1.1.1 Introduction Page 2

1.1.2 Getting-Started – Preparing the Tools Page 2

1.1.3 Instructions Page 3

1.2 AssemblyProcedures–VPV16–164

1.2.1 Introduction Page 9

1.2.2 Getting Started – Repair Kit, Seal Kit and Shaft Seals Page 9

1.2.3 Instructions Page 11

Section 2: Compensator

2.1 Disassembly Procedures – Two-Stage Compensator Page 19

2.2 Assembly Procedures – Two-Stage Compensator

2.2.1 Getting started Page 22

2.2.2 Instructions Page 23

2.3 Disassembly Procedures – Single Stage Compensator Page 27

2.4 Assembly Procedures – Single Stage Compensator

2.4.1 Getting Started Page 29

2.4.2 Instructions Page 30

Section 3: Compensator Adjustment Procedures

3.1 Proper Setting of the Thrust Screw Page 32

3.2 Adjustment Procedures – Single Stage Compensator Page 34

3.3 Adjustment Procedures – Two-Stage Compensator Page 36

3.4 Multi-Pressure Compensators

3.4.1 Solenoid Two-Pressure Control Page 38

3.4.2 Solenoid Vented Page 40

3.5 Load Sense Page 42

3.6 TorqueLimiter Page 45

3.7 MaximumFlowLimiter Page 49

Section 4: System Preparation Procedures

4.1 Fluids, Filters & System Preparation Page 50

4.2 Pump Installation Procedures Page 52

4.3 System Start-Up Procedures Page 53

4.4 Trouble Shooting Page 54

Section 5: Additional Information

5.1 DimensionsofDoublePumps Page 57

5.2 Bearing Puller for VPV Pump – Instructions for Use Page 58

Table of Contents VPV 16–164, 3000 PSI

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1.1 Disassembly Procedures –VPV 16–164

2 Service and Repair Guide

1.1.1 Introduction

The disassembly shown on the following pages covers the Bosch VPV 16cc –164cc variable volume vane

pumps.The complete disassemblyprocedures are similarfor all pumps.Any differences betweenthe

pump models are described in additional notes.

1.1.2 Getting Started – Preparing the Tools

erutxiFnedooWfoyrtemoeGdednemmoceR:2elbaT VPV 61 23/52 08/36/54 461/031/001

)mm(hcni–retemaiD3

)68(4

)501(5

)131(6

)651(

)mm(hcni–thgieHmuminiM2)15(2

)76(3)67(3

)89(

ylbmessasiDpmuProfslooT:1elbaT VPV 61 23/52 08/36/54 461/031/001

revoC hcnerWnellA swercSpaCdaeHtekcoS4 mm8mm01mm41mm71

lavomeR–setalPdnarevoC srevirdwercSedalBtalF2

lavomeR–senaV sreilPesoNeldeeNgnoLforiaParosrezeewT

senaV11senaV11senaV11senaV22

revoCsaiB+rotasnepmoC hcnerWnellA swercSdaeHtekcoS4×2mm6mm6mm8mm8

wercStsurhT hcnerWnellAmm8–23/52/61VPV 7820325359:tekcoSrennapSpils-noN–08/36/54VPV 6820325359:tekcoSrennapSpils-noN–461/031/001VPV

tuNkcoLwercStsurhT —hcnerWrennapSecaFelbatsujdA 1etoN

lavomeR–gniraeB —relluPgniraeBhcsoB 2etoN

lavomeR–laeStfahS hcnuPdaeHdnuoRdnaremmaH

Note 2 (Fig. 1.1.2-c):

It is recommended that the four different sizes of bearing puller tools be

purchased as a complete kit to guarantee that the proper tool is on hand

for any size VPV (Part-No. 9 511 230 691). Please see Section 5.2:

BearingPulleronPage58. Fig. 1.1.2-c

Note 1 (Fig. 1.1.2-b):

For older VPV 16–32 models, a crowfoot may be needed for the

disassembling of the thrust screw locknut. This crowfoot is included in

the Bosch VPV tool kit (Part-No. 9 511 230 557).

Fig. 1.1.2-b

Wooden Fixture (Fig. 1.1.2-a):

As an aid for repairing the VPV pump, we recommend building a

woodenfixture.Please see the differentinsidediameters for each pump

inTable 2.

Fig. 1.1.2-a

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1.1 Disassembly Procedures –VPV 16–164

Service and Repair Guide 3

1.1.3 Instructions

1. Remove the straight key from the keyway of the shaft and

place the pump shaft side down into the wooden fixture

(Fig. 1.1.3-1). See Page 2 for details and illustration of

woodenfixture.

Fig. 1.1.3-1

Note 3:

For disassembling the larger pumps, a great amount of

torque will be needed to loosen the cover bolts. Therefore,

we recommend loosening the bolts before removing the

pump from the motor-unit. Use a socket or extend the length

of your Allen wrench and make sure to clamp the pump

safely (Fig. 1.1.3-2b).

3. Insert flat blade screwdriver into the slots provided on

each side of the cover. Pry the cover assembly loose using

equal force on each screwdriver (Fig. 1.1.3-3). After the

cover is loose, carefully remove it by hand and set it aside

in a clean area.

Fig. 1.1.3-3

2. Remove the four socket head cap screws on the cover by

usingtheappropriatesizeAllenwrench(Fig. 1.1.3-2a).

Fig. 1.1.3-2a

Fig. 1.1.3-2b

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1.1 Disassembly Procedures –VPV 16–164

4 Service and Repair Guide

4. In order to remove the port plate from the cover, insert flat

blade screwdriver into the slots between the port plate and

cover and pry the port plate loose (Fig. 1.1.3-4a). After the

port plate is loose, carefully remove it by hand.

Note 4:

When disassemblingaVPV45–164,pleasepayattention

not to loosen the ratio valve cartridge that is located in the

cover (see Fig. 1.1.3-4b and c) and the ratio valve sealing

assembly that is located on the back of the cover port plate.

The ratio valve cartridge is an essential part of the pump and

is not a wear item, so it is not part of the repair kit. Fig. 1.1.3-4a

6. Remove the vanes from the rotor by using a small pair of

tweezers or long needle nose pliers (Fig. 1.1.3-6). Caution

should be exercised not to nick or score the vanes,

pressure ring and rotor.

Fig. 1.1.3-6

5. Remove the cover O-ring (Fig. 1.1.3-5).

Fig. 1.1.3-5

Fig. 1.1.3-4c

Radio Valve Cartridge

SECTION B-B

Scale: 2X

Fig. 1.1.3-4b

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1.1 Disassembly Procedures –VPV 16–164

Service and Repair Guide 5

8. Remove the four socket head screws on the compensator

by using the appropriate Allen wrench (Fig. 1.1.3-8) and

removethe compensator.

Fig. 1.1.3-8

7. Remove the rotor shaft (Fig. 1.1.3-7).

Fig. 1.1.3-7

9. Carefully remove the control piston and spring (Fig. 1.1.3-9a and b) being careful not to nick or

scratch the piston or the piston bore.

Fig. 1.1.3-9a Fig. 1.1.3-9b

10. Remove the four socket head cap screws on the bias cover

by using the appropriate Allen wrench (Fig. 1.1.3-10) and

remove the bias cover. The bias cover is over the bias

piston or the smaller piston opposite the control piston.

Carefully remove the bias piston ensuring that the bias

piston and the piston bore are not scratched or nicked.

Fig. 1.1.3-10

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1.1 Disassembly Procedures –VPV 16–164

6 Service and Repair Guide

11. For VPV 45–164 pumps, loosen the thrust screw lock ring

by using a spanner wrench (Fig. 1.1.3-11). For VPV 16–32

pumps, loosen the locknut with an adjustable wrench (not

pictured). Please see Note 1 on Page 2 when

disassemblingthe VPV 16–32.

Fig. 1.1.3-11

12. Remove the thrust screw (Fig. 1.1.3-12a) by using the

appropriate spanner socket or Allen wrench, from the

Bosch VPV repair tool kit.

Fig. 1.1.3-12a

Note 5:

In addition to the thrust screw, the VPV 45–164 has a

thrust block (Fig. 1.1.3-12b). Remove the thrust block from

the body.

Fig. 1.1.3-12b: Thrust Block for VPV 45–164

13. Remove the pressure ring (Fig. 1.1.3-13).

Fig. 1.1.3-13

Courtesy of CMA/Flodyne/Hydradyne ▪Motion Control ▪Hydraulic ▪Pneumatic ▪Electrical ▪Mechanical ▪(800) 426-5480 ▪www.cmafh.com

1.1 Disassembly Procedures –VPV 16–164

Service and Repair Guide 7

17. To drive out the shaft seal take a round head punch and

carefullytapit outfromthecover side of pump (Fig.1.1.3.-17).

Remove the shaft seal.

Fig. 1.1.3-17

16. If the bearings are damaged and need to be replaced,

remove the bearings in the body and the cover by using the

Bosch VPV bearing puller (Fig. 1.1.3-16). Please see

Section 5.2 –Bearing Puller for more details.

Fig. 1.1.3-16

15. Remove the port plate from the body by carefully grabbing

the port plate at the thru-hole location (Fig. 1.1.3-15). After

the plate has been lifted out, set it aside. Be careful not to

scratch or nick the coating on the port plates. Leave the

seals in the port plate.

Fig. 1.1.3-15

14. Remove the spacer ring (Fig. 1.1.3-14).

Fig. 1.1.3-14

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1.1 Disassembly Procedures –VPV 16–164

8 Service and Repair Guide

After the pump has been completely disassembled, all parts must be thoroughly cleaned with clean

solvent. At this time inspect and determine which parts need to be replaced. In a major overhaul, itis

recommended that both bearings and all seals be replaced regardless of their condition. Kits containing all

seals are available for use in the repair of this pump.

When ordering repair parts it is necessary to provide either the alpha-code or the 10-digit part-number

which will be0 513 xxx xxx,describing the pump. Thisinformation can be foundon the nameplate attached to

the rear cover of the pump body. We always prefer the 10-digit part number, but the long hydraulic code is

alsosufficient.

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