Bosch VPV 16 Installation and operating manual

Hydraulics
VPV Vane Pump
Whisper™ Pump
Service and Repair Guide
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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: [phone]or
Fax: [phone]
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
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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
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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
3
/ 8 )68(4
1
/ 8 )501(5
1
/ 8 )131(6
1
/ 8 )651(
)mm(hcni–thgieHmuminiM2)15(2
5
/ 8 )76(3)67(3
7
/ 8 )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
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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
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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
BB
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
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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
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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
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1.1 Disassembly Procedures –VPV 16–164
Service and Repair Guide 7
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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
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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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