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Summary of Contents for Bosch Whisper VPV16
- Page 1 Hydraulics VPV Vane Pump Whisper™ Pump Service and Repair Guide...
- Page 2 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 accomplish maximum performance and a long life for the Bosch VPV 16cc–164cc (1 in...
- Page 3 Service and Repair Guide Table of Contents VPV 16–164, 3000 PSI Section 1: Pump 1.1 Disassembly Procedures – VPV 16–164 1.1.1 Introduction Page 2 1.1.2 Getting-Started – Preparing the Tools Page 2 1.1.3 Instructions Page 3 1.2 Assembly Procedures – VPV 16–164 1.2.1 Introduction Page 9 1.2.2 Getting Started –...
- Page 4 1.1 Disassembly Procedures – VPV 16–164 1.1.1 Introduction The disassembly shown on the following pages covers the Bosch VPV 16cc –164cc variable volume vane pumps. The complete disassembly procedures are similar for all pumps. Any differences between the pump models are described in additional notes.
- Page 5 Service and Repair Guide 1.1 Disassembly Procedures – VPV 16–164 1.1.3 Instructions 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 wooden fixture.
- Page 6 Service and Repair Guide 1.1 Disassembly Procedures – VPV 16–164 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.
- Page 7 Service and Repair Guide 1.1 Disassembly Procedures – VPV 16–164 Remove the rotor shaft (Fig. 1.1.3-7). Fig. 1.1.3-7 Remove the four socket head screws on the compensator by using the appropriate Allen wrench (Fig. 1.1.3-8) and remove the compensator. Fig. 1.1.3-8 Carefully remove the control piston and spring (Fig.
- Page 8 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.
- Page 9 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 17.
- Page 10 Service and Repair Guide 1.1 Disassembly Procedures – VPV 16–164 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, it is recommended that both bearings and all seals be replaced regardless of their condition.
- Page 11 1.2 Assembly Procedures – VPV 16–164 1.2.1 Introduction To guarantee proper operation of the VPV pump, Bosch recommends replacing all important pump parts by using the Bosch repair kit and the Bosch VPV Seal kit. 1.2.2 Getting Started – Repair Kit, Seal Kit and Shaft Seals Table 3 shows which Repair Kit corresponds to which VPV pump.
- Page 12 Service and Repair Guide 1.2 Assembly Procedures – VPV 16–164 For applications using water-glycol, please use the shaft seals listed in Table 6: For all other applications, please use the shaft seals listed in Table 7: c i l c i l Figure 1.2.2 Pump Components with numbered Repair and Seal Kit Parts —...
- Page 13 Service and Repair Guide 1.2 Assembly Procedures – VPV 16–164 Preparing the tools a l l o i t t a l & n i r e t i & e t i c i l a l l o i t o i t c i l 1.2.3 Instructions...
- Page 14 Service and Repair Guide 1.2 Assembly Procedures – VPV 16–164 Replace the bearings for the body and cover . The body and cover bearings are identical. Place the bearings into the bearing bores and thoroughly lubricate the bearing I.D. ’ s with clean hydraulic fluid.
- Page 15 Service and Repair Guide 1.2 Assembly Procedures – VPV 16–164 Replace the seals and back-up rings on the backside of both port plates (Port plate with seals see Fig.1.2.3-4a) Install seals on each port plate. Fig. 1.2.3-4a . g i .
- Page 16 Service and Repair Guide 1.2 Assembly Procedures – VPV 16–164 Place the port plate into the pump body (Fig. 1.2.3-5a). Note that the pins fit in the provided holes. Completely lubricate the port plate’s wear surface with clean hydraulic fluid. Fig.
- Page 17 Service and Repair Guide 1.2 Assembly Procedures – VPV 16–164 Assemble the control piston and spring through the clearance hole in the spacer ring (Fig. 1.2.3-8a and b). Lubricate the piston before installing. Fig. 1.2.3-8a Fig. 1.2.3-8b Thoroughly lubricate the pressure ring with clean hydraulic fluid.
- Page 18 Service and Repair Guide 1.2 Assembly Procedures – VPV 16–164 11. For the VPV 45–164, install the thrust screw lock ring by using the adjustable face spanner wrench (Fig. 1.2.3-11). For the VPV 16–32 use and Allen head wrench to tighten the thrust screw.
- Page 19 Service and Repair Guide 1.2 Assembly Procedures – VPV 16–164 The O-rings are included both as part of the pump and the compensator repair kit. Note 9: When lubricating O-rings and the seals of the compensator, please use a minimum amount of grease or petroleum jelly. Mount the compensator to the pump and torque the four socket head cap screws by using the appropriate Allen wrench (Fig.
- Page 20 Service and Repair Guide 1.2 Assembly Procedures – VPV 16–164 16. Insert O-ring on body pilot bore (Fig. 1.2.3-16a). A light grease or petroleum jelly may be used to hold the O- ring in place while installing the cover. Fig. 1.2.3-16a Note 11: For the VPV 45–164 insert a second O-ring into the...
- Page 21 Service and Repair Guide 2.1 Disassembly Procedures – Two-Stage Compensator Shown in Fig. 2.1 are the Bosch two-stage compensators rated at 3000 PSI for the VPV 16–32 (left side) and the VPV 45–164 (right side). Following are the complete disassembly procedures. Any differences between the different compensator models are described in additional notes.
- Page 22 Service and Repair Guide 2.1 Disassembly Procedures – Two-Stage Compensator Remove the plug from the second stage body by using the appropriate Allen wrench (Fig. 2.1-4). Fig. 2.1-4 Remove the three socket head cap screws that attach the second stage body to the first-stage body by using the appropriate Allen wrench (Fig.
- Page 23 Service and Repair Guide 2.1 Disassembly Procedures – Two-Stage Compensator Remove the first stage adjustment screw adapter by using an adjustable wrench (Fig. 2.1-7a). Remove the differential spring, spring seat and stop tube (see Fig. 2.1-7b). Please note that the stop tube has been removed from the most current compensator design and replaced with an external washer and snap ring.
- Page 24 Service and Repair Guide 2.2 Assembly Procedure – Two-Stage Compensator 2.2.1 Getting Started To guarantee proper operation of the two-stage compensator Bosch recommends replacing all compensator seals included in the Bosch compensator seal kit. Please use the following compensator seal kits: Fig.
- Page 25 Service and Repair Guide 2.2 Assembly Procedure – Two-Stage Compensator 2.2.2 Instructions Thoroughly lubricate the compensator spool with clean hydraulic fluid. Make sure there are no burrs on the compensator spool and insure that the spool has no residual magnetism. Spools that are magnetic will attract metallic particles and damage the compensator body or spool.
- Page 26 Service and Repair Guide 2.2 Assembly Procedure – Two-Stage Compensator Install the first stage differential spring adjustment screw adapter as one assembly into first stage body (Fig. 2.2.2-4). Torque to 708-888 in-lbs (80-100 Nm). Fig. 2.2.2-4 Replace the back plug with the O-ring and insert it into first stage compensator body.
- Page 27 Service and Repair Guide 2.2 Assembly Procedure – Two-Stage Compensator Replace the poppet seat with the O-ring and insert it into the second stage body using a large screwdriver (Fig. 2.2.2-7). Avoid damaging any of the O-ring sealing surfaces. Torque to 168 in-lbs (19 Nm) Fig.
- Page 28 Service and Repair Guide 2.2 Assembly Procedure – Two-Stage Compensator 10. Torque the two socket head screws to 44-62 in-lbs (5-7 Nm) (Fig. 2.2.2-10). Fig. 2.2.2-10 11. Prior to mounting the second stage to the first stage body, insure that all O-rings (2 pcs.) are in place on the mating surface of the second stage body (Fig.
- Page 29 Service and Repair Guide 2.3 Disassembly Procedure – Single Stage Compensator Shown is the Bosch single stage compensator (Fig 2.3). Following are the complete disassembly procedures. The single stage control is normally only available for the VPV 16–32. Fig. 2.3 Remove the roll pin on the backside of single stage compensator.
- Page 30 Service and Repair Guide 2.3 Disassembly Procedure – Single Stage Compensator Remove the hex head plug on the side of single stage compensator by using the appropriate Allen wrench (Fig. 2.3-3). Fig. 2.3-3 Remove the hex head plug opposite to the adjustment knob by using the appropriate Allen wrench (Fig.
- Page 31 2.4.1 Getting Started To guarantee proper operation of the single stage compensator Bosch recommends replacing all compensator seals included in the Bosch compensator seal kit. Please note that for the single stage compensator two different designs exist (Fig. 2.4.1-a). The old design needs a “teardrop O-ring”...
- Page 32 Service and Repair Guide 2.4 Assembly Procedures – Single Stage Compensator 2.4.2 Instructions Thoroughly lubricate the compensator spool with clean hydraulic fluid. Insert the compensator spool into the single stage body by holding the rounded end and inserting the small round end first (Fig. 2.4.2-1). Replace the O-ring and back-up ring on the...
- Page 33 Service and Repair Guide 2.4 Assembly Procedures – Single Stage Compensator Replace the shock clipper plug including the O-ring the side of single stage compensator and insert it by using the appropriate Allen wrench (Fig. 2.4.2-5). Torque to 150-186 in-lbs (17-21 Nm). Fig.
- Page 34 Service and Repair Guide 3.1 Proper Setting of the Thrust Screw Make sure the pump is in “deadhead” condition before attempting adjustment of the thrust screw. The “deadhead”, or compensated condition, can be reached by blocking the outlet port by shutting off downstream valves which means that the output flow is blocked.
- Page 35 " Allen wrench is required. For the VPV 45–164 a spanner wrench is required. The spanner is available in the VPV Tool Kit, Bosch part number 9 511 230 557. • While observing a pressure gage turn the thrust screw clockwise to increase pressure, or counter- clockwise to decrease pressure, to the appropriate thrust screw pressure in the proper table above.
- Page 36 Service and Repair Guide 3.2 Adjustment Procedures – Single Stage Compensator Pressure Port Spool Bias Piston Control Piston Spring Note: One single common leakage connection in Fig. 3.2-1. The multiple leakage connections shown are only for functional representation Fig. 3.2-1 The single stage compensator consists of a spool, spring and adjusting screw, which are assembled in a body and bolted to the pump body.
- Page 37 Service and Repair Guide 3.2 Adjustment Procedures – Single Stage Compensator When there is no resistance to pump flow, the spring will force the spool into the spring offset or “bottomed out” position (Fig. 3.2-4) shown. In this position, fluid from the pressure port can flow through the compensator to the control piston and allow system pressure to be applied to the control piston.
- Page 38 Service and Repair Guide 3.3 Adjustment Procedures – Two-Stage Compensator The two-stage control works exactly the same as the single stage control. However, instead of loading the spool with a spring, it is hydraulically loaded. To do this, a small relief valve referred to as the second stage is connected to the spring chamber.
- Page 39 Service and Repair Guide 3.3 Adjustment Procedures – Two-Stage Compensator As system pressure increases, the pressure at the ends of the spool is always equal until it reaches the second stage setting. At that point the relief valve (second stage) will open and limit the pressure in the bias spring chamber by allowing fluid from the chamber to flow to tank.
- Page 40 Service and Repair Guide 3.4 Multi-Pressure Compensator Multi-pressure pump control can markedly reduce horsepower demand and heat generation during periods of idle time or time in the machine operating cycle when maximum pressure is not required. The modular design of the standard two-stage compensator lends itself to variable preset multi-pressure control arrangements with integral or remotely located valving.
- Page 41 Service and Repair Guide 3.4 Multi-Pressure Compensator Pump Control MTG. Datum ‘T’ Solenoid Operated Two-Pressure Unless Otherwise Specified 1.73 and Optional Quick Connect All Dimensions are Normal. (43.9) Pump Normally Closed Normally Open Pump c L 1.75 (44.5) 1.88 1.38 1.63 (47.8) (35.1)
- Page 42 Service and Repair Guide 3.4 Multi-Pressure Compensator 3.4.2 Solenoid Vented 1.73 (43.9) Pump Control MTG. Datum ‘T’ Soleniod Operated Two-Pressure and Optional Quick Connect Pump Normally Closed Normally Open Pump c L 1.75 (44.5) 1.88 1.38 1.63 (47.8) (35.1) (41.4) N.P.T.F.
- Page 43 Service and Repair Guide 3.4 Multi-Pressure Compensator Note: One single common leakage connection in Fig. 3.4.2-2. The multiple leakage connections shown are only for Fig. 3.4.2-2 functional representation Figure 3.4.2-2 shows a hydraulic representation of a solenoid vented compensator. Once again, the solenoid must be closed to begin compensator adjustment.
- Page 44 Service and Repair Guide 3.5 Load Sense The purpose of the load sensing flow control is to maintain constant flow regardless of changes in load or pump shaft rotational speed. This is accomplished by using an external metering valve and continually sensing pressure drop across this valve with a pilot line.
- Page 45 Service and Repair Guide 3.5 Load Sense All orifices must be non-pressure compensated and sharp edged for temperature stability. If only low accuracy is needed, the DP of a four-way valve or other two-way is generally useable. Remember that at least 100 PSI (200 PSI for VPV 100–164) DP must be developed at the minimum flow rate or the LSFC will not work well.
- Page 46 Service and Repair Guide 3.5 Load Sense Load Sensing Flow Compensator Control 1st Stage Changeable Orifice Load Metering Throttle Valve Fig. 3.5-2 o l f o l f i f i r l l u i f i r t s i n i t d i r LSFC Flow vs.
- Page 47 SAE connections. Torque limiting controls featuring BSPP connections may be offered in the future. If your application requires BSPP connections, please contact the factory for availability. Bosch also plans to develop torque limiter control options with built-in load sensing, solenoid vent and solenoid multi-pressure options.
- Page 48 Service and Repair Guide 3.6 Torque Limiter Fig. 3.6-2 shows that the second stage pressure adjustment (pressure cut-off curve) will over-ride the torque limiter adjustment (torque cut-off curve) when the two intersect. This feature limits the maximum pressure of the pump. Torque Limiter Cut-off Points Pressure Cut-off Curve Torque Cut-off Curves...
- Page 49 Service and Repair Guide 3.6 Torque Limiter Torque Limiter Adjustment Control Spring Follower Spring Cone Poppet Second Stage Pressure Adjustment Knob Remote Port of Second Stage of Pressure Compensator Movable Seat From First Stage Spring Chamber First Stage of Pressure Compensator Push Rod Contacting Lip of Control Piston Moves in Direction Shown Fig.
- Page 50 Service and Repair Guide 3.6 Torque Limiter o i t t s i t s i l l u n i t t s i n i r n i r Control Piston Fig. 3.6-6 Setting the Maximum Deadhead Pressure (Second Stage Setting) Caution: VPV torque limiter adjustment stems that have the adjustment knob removed pose special concerns when the pump is re-started.
- Page 51 Service and Repair Guide 3.7 Maximum Flow Limiter Volume Control Lock Nut Bias Cover Piston . n i < < • During initial start-up, volume should be at least 50% of the maximum flow. • Only make adjustments to volume control with pump running at full flow and low pressure while observing output flow.
- Page 52 Fluid Recommendations Bosch recommends the use of premium quality hydraulic fluids, such as Mobil DTE 25, DTE 26 or equivalent, with zinc anti-wear additives. The viscosity grade selected for your system should be based on the information in Table 32.
- Page 53 When converting your system from petroleum base fluids to water-glycol, water-in-oil emulsion, or synthetic fluids contact the factory and/or your fluid supplier for system preparation instructions. Refer to Bosch publication S-107, “Fire Resistant Fluids. ” We recommend that the users of fire resistant fluids obtain a copy of the NFPA publication entitled...
- Page 54 The case drain lines from multiple pumps in a combination should independently be plumbed back into the reservoir to prevent problems. Bosch recommends not to install check valves in case drain lines if possible. If necessary, Bosch strongly recommends “swing style” check valves which have low mass and will limit case drain spikes.
- Page 55 If your pump incorporates the optional screw volume control, Bosch recommends not reducing the pump’s output flow by more than 50% on start-up (pump-flow is reduced by turning the adjustment screw clockwise).
- Page 56 Service and Repair Guide 4.4 Trouble Shooting l a i n i l g i l . t n g i l h t i " 6 l a t g i l l l i i t n c i f y l t e r i .
- Page 57 Service and Repair Guide 4.4 Trouble Shooting l a i o i t l a t n i l c i r o i t o i t o i t o i t n i l l l a t i f n i t .
- Page 58 Service and Repair Guide 4.4 Trouble Shooting l a i l i o t I . a i t n i r c i f o i t e f i n i r n i l g i l .
- Page 59 Service and Repair Guide 5.1 Dimensions of Double Pumps ] ) t " 0 " 5 " 5 " 4 " 5 " 5 " 4 " 5 " 5 " 4 " 0 " 5 " 4 " 9 "...
- Page 60 5.2 Bearing Puller for VPV Pump – Instructions for Use Introduction This instruction sheet will familarize the technician with the proper use of the bearing puller tool for Bosch VPV series pumps. The bearings are pressed in at the factory with pressures up to 4000 PSI. When rebuilding a pump, a significant amount of force is necessary to back out the bearings without damaging the bore.
- Page 61 Service and Repair Guide 5.2 Bearing Puller for VPV Pump – Instructions for Use Removing the Bearing Once the pump is disassembled, lay the cover section of the VPV on a flat work surface. NOTE: This procedure can also be performed with cover section stilll in place on the pump, but it is somewhat more difficult and awkward.
- Page 62 Service and Repair Guide 5.2 Bearing Puller for VPV Pump – Instructions for Use Tighten the hex nut as far down on the pressure screw as easily possible (Fig. 5.2-6). Fig. 5.2-6 Using box-end and/or open-end wrenches, hold the pressure screw in place while tightening the hex-nut, until the bearing breaks loose (Fig.
- Page 64 FAXline: (888) 308-3424 FAXline: (888) 308-3424 www.boschat.com www.boschat.com www.boschat.com EUROPE Robert Bosch GmbH Geschäftsbereich Automationstechnik Postfach 30 02 07 D-70442 Stuttgart Telefax (0711) 811-7712 For more information, you may contact your nearest Bosch distributor: Publication No. 9 535 233 872 7/00...