PERMCO Bushing Series User manual

Bushing Series Service Manual

Tool List and Kits
1. Arbor Press
2. Bearing Puller
3. Bushing Removal Kit
4. Collets
5. Bushing Installation Kit
6. Soft Face Hammer
7. Medium Grit Stone
8. Oil and Grease
9. Torque Wrench
10. Bench Vise
11. Crayon or Marker
12. Permatex Aviation
Form-A-Gasket #3
13. Snap Ring Pliers
14. Lip Seal Install Plug
15. Motor Seal Expansion
Sleeve
Bushing Insertion Kits
124 Series - T-1194
197 Series - T-1188
257 Series - T-1175
360 Series - T-1199
Kits includes insertion tool and
guide or see sketches to right.
Tool List
Motor Seal Expansion Sleeve
Series A Dia. B Dia. C D Collet OTC #
124 0.920/0.940 0.830/0.850 0.085/0.095 1.22/1.28 T-1195 33863
197 Stock Stock 0.085/0.095 Stock T-1170 33863
257 1.260/1.280 1.140/1.160 0.060/0.070 As Shown T-1174 33865
360 1.372/1.382 1.250/1.260 0.100/0.120 As Shown T-1202 33865
Series A B Dia. C Dia. D Dia. E F Dia. G. Dia.
124 1.307/1.312 0.939/0.941 1.057/1.059 2.00 1.298/1.302 2.000 1.067/1.069
197 1.410/1.415 1.119/1.121 1.275/1.277 2.00 1.395/1.400 2.375 1.285/1.287
257 1.811/1.815 1.286/1.288 1.443/1.445 1.94 1.800/1.804 1.940 1.453/1.457
360 2.002/2.004 1.496/1.498 1.655/1.657 2.50 1.999/2.001 2.500 1.665/1.667
Series Tool Part # A B Dia. C Dia.
124 Q-1956-5 2.500 0.885/0.889 0.940/0.944
257 Q-1956-3 2.500 1.250/1.254 1.286/1.290
360 Q-1956-2 2.500 1.259/1.263 1.379/1.383
Bushing Removal
Need 1 kit (T-1243) plus the collet for each series or
the OTC collet modified per sketch shown above.
Bushing Insertion
“C” R 0.020 MAX.
“A” DIA.
“B” DIA.
“D”
“D” DIA.
0.50 “A” 0.25
“B” DIA.
“C” DIA.
0.03 x 45°
0.06 x 45°
“E”
“G” DIA.
0.06 x 45°
4 Places
“B” DIA.“C” DIA.
“A”
“F” DIA.
1

Bushing Series Service Manual
1. Retaining Ring
2. Outboard Bearing (Optional)
3. Shaft Seal
4. Shaft End Cover
5. Journal Bushing
6. Back up Ring
7. Seal Ring
8. Thrust Plate
9. Housing Gasket
10. Integral Gear Set
11. Continental Gear Set
12. Dowel Pin
13. Gear Housing
14. Port End Cover (Single)
15. Washer
16. Hex Head Bolt
17. Bearing Carrier
18. Connecting Shaft
19. Port End Cover (Tandem)
20. Tie Bolt
21. Hex Nut
22. Spacer (Motor only)
23. Check Valves for Motors,
Plugs according to BOM
Single Port
End Cover
15
12
21
15
5
5
6
7
8
9
11
12
9
8
7
6
5
5
12
12
13
19
20
15
20
21
21
17
18
15
16
15
12
15
16
16
15
14
13
12
12
5
5
6
7
8
9
12
10
9
8
7
6
5
5
4
3
2
1
23
23
22
Multiple Sections
Tandem Port
End Cover
General Notes
1. Read all
instructions prior
to disassembly
and assembly to
familiarize yourself
with all steps
required.
2. All areas and tools
should be clean in
the work area, and all
parts clean and wiped
with a lintless cloth
before assembly.
3. Make sure all
components are
prepared and marked
(if needed) for the
correct rotation.
4. Use only Geniune
Permco parts, as
other manufacturers’
parts may not fit in all
Permco assemblies.
5. Refer to bushing
diagrams included for
each series on page
9-10.
6. Tear down and
assembly shown is a
P257 2 section pump.
2

Start Disassembly
1.
Place pump in vise as
shown and scribe a
line down the pump
from port end cover
to shaft end cover.
This line will be used
for reassembling.
DO NOT GRIP
ON OR NEAR
ANY MACHINED
SURFACES DURING
ASSEMBLY OR
DISASSEMBLY
2.
Remove the 4 fasteners
with a socket or impact
wrench.
4.
Remove the
thrust plate and
inspect.
(See Page 8)
3.
Remove port end cover by inserting screwdrivers into pry-
pockets on the side of the gear housing. Be careful not to
damage machined surfaces.
5.
Multiple Units Only Remove gear set keeping gears
together. Remove thrust plate from bearing carrier.
Examine gear set and thrust plate for replacement.
(See Page 8)
6.
Multiple Units Only
Remove gear housing
from bearing carrier
by using screwdrivers
inserted into the pry-
pockets. Examine for
replacement.
(See page 8)
3

Bushing Series Service Manual
8.
Remove the
connecting shaft,
gears, thrust
plates, and
gear housing
by repeating
steps 4-6. Refer
to page 8 for
replacement.
7.
Multiple Units Only
Lift bearing carrier
from gear housing.
9.
Inspect all
bushings
and refer to
page 8 for
replacement.
10.
If the unit is equipped with an outboard bearing, first
remove the retaining ring as shown. If unit has snap ring,
remove it with snap ring pliers.
11.
Use a bearing puller to remove outboard bearing, if needed.
12.
Remove the shaft seal by placing a screwdriver against the
back of seal and tapping as shown.
4

Single and Tandem Assembly
1.
Stone all faces with a medium grit stone.
2.
Deburr all bushing bores with emery cloth to assure
bushings do not become galled during installation.
3.
Apply a thin film of Permatex Aviation Form-A-Gasket #3
around the O.D. of the lip seal. With the metal side up,
press the seal into bore until it is flush with the recessed
face.
4.
It is recommended
that insertion tools
manufactured by
Permco be used for
pressing in bushings.
Refer to sketches for
bushing orientation
and plug (check valve)
location.
1. Shaft End Cover, Gear Housing, Bearing Carrier, and Port End Cover: Stone or file mating surfaces to remove
any raised metal generated in shipping or handling.
2. Gear Shafts, Gears: Stone faces of gears to remove any raised metal generated in shipping and handling.
3. Bearing Carrier and Port End Cover: Probe all bushing drain passages to insure that none are blocked.
4. Gear Housing: Use a deburring knife to break the edge on the gear bores and dowel pin holes to ease as-
sembly. Clean foreign material from dowel pin holes and gasket grooves.
5. Shaft End Cover, Bearing Carrier, and Port End Cover: Use a deburring knife to break the edge of bushing and
dowel pin holes to ease assembly. Clean foreign material from dowel pin holes. Use a flapper wheel or emery
cloth on edge of the bushing bores to create a small radius.
6. Shaft End Cover, Bearing Carrier, and Port End Cover: Mark the faces to indicate low and high pressures.
This will ensure proper bushing orientation.
5

Bushing Series Service Manual
7.
Install spirolox retaining ring as shown.
8.
Start pin in hole straight, and tap lightly with a soft
hammer.
9.
Grease gasket seal
and place in groove
of gear housing.
Place gear
housing on
dowel pins and
tap flush with
shaft end cover.
Make sure large
core of 124,
197, or 360 is on
inlet side.
10.
Place a liberal amount of grease in plate
groove(A). Place rubber element in groove
with recess up for nylon backup.(B)
Place backup in recess of
seal ring.(C)
5.
Install bushings with the lube grooves and butt
joints as shown on Page 9-10.
124 Series shown in this example
A
B
C
PUMP
6.
If unit has
an outboard
bearing install
as shown. For
motors install
spacer (22)
first.
6

Single and Tandem Assembly
12.
Squirt oil into bushings and on thrust plates and slide gears
into gear housing. For motors protect the seal by placing a
seal instertion sleeve onto gear.
13.
Slide thrust plate over gears with seals facing up and
trapping pocket on pressure side. Tap dowel pins into gear
housing.
14.
Multiple Units Only Position bearing carrier over gear
journals and dowel pins.
Gently tap until the
parts are together.
Check bearing
carrier port
orientation.
15.
Multiple Units Only Insert connecting shaft into the
drive gear spline.
Place the second
gear housing on the
bearing carrier by
repeating steps 8-9.
11.
Slip the thrust plate into the gear housing with the “T” or
“U” shaped trapping pocket up and on the outlet side.
7

Bushing Series Service Manual
16.
Multiple Units Only
Repeat steps 10 - 13
using continental gears
in step 12.
17.
Position port end cover
over gear journals and
dowel pins. Gently tap
until the parts are
together.
18.
Place 4 washers on the port end cover. Thread 4 clean and dry fasteners
into the shaft end cover, and tighten alternately in a diagonal pattern.
Rotate the drive shaft with vise grips and torque to specification shown in
table below.
Guide for Replacing Parts
Thrust Plates
Replace plates if scored, eroded, pitted, or
discolored from heat.
Gears
Replace if any scoring on journals is found. Also
fretting, nicking, scoring, or grooving of teeth
surfaces.
Gear Shafts
Same as gears, but also replace if any wear is
found in seal area. Also replace if any wear on
splines or keyway is found.
Gear Housing
Replace if wear exceeds 0.005” below bore.
Dowel Pins
If the dowel pin is loose in the casting, either the
dowel pin or casting must be replaced
Bushings
Replace if scoring, discoloration, or signs of copper
showing through. If gear set is replaced, the
bushings should also be replaced.
8

Bushing Install
P124/M124
P197 M197
OUTLET
INLET
Install bushings as shown
with butt joints located at
12:00 and 6:00 o’clock.
Bushings must be flush to
slightly below surface.
Install P197 series bushings with lube grooves and butt joints as shown for optimum performance. However,
bushings may alternately be installed per M197 diagram and must be flush to slightly below the surface.
9

Bushing Series Service Manual
P257/M257
P360/M360
Install bushings with lube
grooves and butt joints as
shown. Bushings must be
flush to slightly below the
surface.
Install bushings as shown
with lube grooves at 12:00
and 6:00 o’clock. Bushing
OD chamfer/ lead-in is down
and square corner must
be flush to slightly below
surface.
OUTLET INLET
10

Bushing Series Service Manual
Testing Procedure
Do not test the unit above the working pressure of the destined application. This will minimize unnecessary
housing wipe and assure optimum volumetric output.
0-15 seconds @ 0 psi 136-150 seconds @ 2500 psi
16-30 seconds @ 500 psi 151-165 seconds @ 0 psi
31-45 seconds @ 0 psi 166-180 seconds @ 3000 psi
46-60 seconds @ 1000 psi 181-195 seconds @ 0 psi
61-75 seconds @ 0 psi 196-210 seconds @ 3500 psi
76-90 seconds @ 1500 psi 211-225 seconds @ 0 psi
91-105 seconds @ 0 psi 226-240 seconds @ 4000 psi
106-120 seconds @ 2000 psi 241-255 seconds @ 0 psi
121-135 seconds @ 0 psi 256-270 seconds @ 4500 psi
Startup and Break-in Procedure
1. Before you begin testing, unscrew the main relief
valve on the circuit.
2. Run the pump for two minutes under no load
conditions, low pressure, and low rpm (600
rpm minimum). If everything seems to function
properly and no unusual sounds are heard, you may
commence testing per the procedure below.
The testing for the Bushing Series units should be
followed closely to assure optimum performance.
When testing a multiple unit, test one section at a
time. Be sure the other sections are being supplied
with adequate oil during the test procedure.
The testing procedure involves loading and unloading
the unit to prevent contamination of the bushings and
bushing journals. In doing so, particles of contaminate
generated during the load cycle will be flushed through
the system during the no load cycle.
Fluid Type and Temperature Conditions
1. The Bushing Series pumps and motors are
compatible with mineral base, water glycol, and
invert emulsion fluids. Fluids such as phosphate
ester may be used in some applications. Please
consult the factory prior to using this type of fluid.
It is recommended that a premium quality hydraulic
fluid with a viscosity range of 150-300 SUS (32-65
cSt.) at 100°F (38°C) be used to assure optimum
performance. The normal operating viscosity range
is between 55-1000 SUS (9-220 cSt.) with a start
up viscosity not to exceed 2000 SUS (440 cSt.).
2. Under normal operating conditions, fluid
temperatures should not exceed 180°F (82°C)
for mineral base fluids and 135°F (57°C) for
water glycol and invert emulsions. If temperatures
greater than these values are required for a
particular application, please consult your Permco
representative or call the factory.
3. To assure maximum performance and life, a
10 micron return line filter with a Beta 10 rating
of 2.2 is required for the system. Testing and
operating a new or serviced unit without proper
filtration will lead to premature failure of the shaft
journals and journal bushings.
Procedures/Notes
11

Bushing Series Service Manual
12

Permco USA
|
1500 Frost Road
|
P. O. Box 2068
|
Streetsboro, Ohio 44241
Copyright © 2015 © Bulletin # BSM-0116 Version 1.0
Permco is a leading manufacturer of high-
pressure hydraulic gear/vane pumps and
motors, flow dividers, intensifiers, and
accessories. Available in a wide variety of sizes
and configurations to suit your application
needs.
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