INSTRUCTION MANUAL = RP**A—* *«—30 (PRESSURE COMPENSATOR TYPE A\ = 1996. 7.28 DAIKIN INDUSTRIES, LTD OIL HYDRAULICS & LUBRICATION DIV. SE-31462. NOMEMCLATURE --—---—~ 3. SPECIFICATIONS AND OPERATING CONDITIONS FOREWORD - CONTENTS 4, STRUCTURE AND FUNCTION 4-1. STRUCTURE ------ 4-2, FUNCTION nanos -+ 4-3, PRESSURE COMPENSATOR CONTRO! 5, INSTALLATION, PIPING AND WIRING 5-1, INSTALLATION AND PIPING ---~~ 5-2. OIL FILLING INTO PUMP HOUSING 5-3. WIRING — ooo - 6. TEST RUN 6-1. Flushing Operation ~ 6-2, Operation 7. MAINTENANCE AND INSPECTION 8. STORAGE 9, TROUBLESHOOTING 10, REFERENCES 10-1. STRUCTUAL DRAWINGS 10-2. OUTPUT POWER RANGE 10-3. ADJUSTMENT OF DISCHARGE FLOW - 10-4, ADJUSTMENT OF DISCHARGE PRESSURE 12 17 7 19 20 al 22 22 23 20 30 34 37 E 3146L4\1. FOREWORD The RP Series ROTOR PUMP is a variable displacenent piston pump integral With an electric motor cooled by hydraulic oi] vhich was designed ani engineered as the hydraulic pressure source for machine tools and genera’ industrial machines, basec on the design concept of thoroughly seeking “Low Noise” and ~ Compact This ROTOR PUMP provides various outstanding features due to its unique structure different fron that of the conventional motor punp ( directly coupled to motor shaft ). Before putting this ROTOR PUMP in initial operation, operator and mainte- hance sian are requested to read carefully this Instruction Manual for proper operation and maintenance control. In order to keep safety, installation and maintenance of ROTOR PUMP should be restricted by skilled person only. ‘This is important to keep the specific pump performance and function throughout a long tine. sE-3146f\2. NOMENCLATURE Aix! | Design Nuaber | Voltage supply + ~ :200/220/220V-50/60/60llz +X :230V-50ltz + Y :880/400/415/400/440/460 ~50/50/50/60/60/60H2 | — Motor Capacity/Poles | 207: 0. 75K /4P +150: 1. SKW/4P 122 2. 2KW/4P | | 87 2 8. TKW/EP | | “550: 5. 5KW/4P Pressure Adjustaent Range s1:15~ 6.9WPa {15 ~ T0kgf/en*) +2245 ~ 13. 7WPa (15 ~ 140kgf/en*) +3534 -~ 20.6MPa | {35 ~ 210kef/en*) } | LL ____ contro + A :Pressure Conpensator Control ee ‘Theoretical Displacenent + 08 : 8.0 cm/rev (cc/rev} +15 14.8 en’/rev (ce/rev + 23 :24.4 cm’/rev (ce/rev} + 38. :37.7 cn*/rev (cc/rev) Series + RP: RP Series Rotor Pump sEe-3146f\3. Specifications and Operating conditions type of electric notor type of hydraulic pump ~ ™@ Poxer supply M Theoretical displacezent of pump -- +08: +15 + 23 + 38 WM Notor capacity/Poles ~~ = 07: (Continous rated output) +15 122: “37 +55 Motor rated current RPOB-07 ~-------~ 3.84 (200¥/50llz) 3. 3.44 (220¥/60H2) 3.48 (220¥/60Hz) I, 1 RPIS-15 - 6.84 (200V/S0H2) 5. 6.0A (200V/60Hz) 3. 5.8A (220V/60Hz) 3. 3. RP15-22 --------- 9.6A (200V/S0Hz) 8. 8.8A (200V/60Hz) 4. 8.44 (220¥/60lz) 4 4 RP23-22 --------- 10.04 (200¥/50iz) 8 9.24 (200V/60Hz) 5. 8.74 (220¥/60llz) 5, 5. RP23-37 --------~ 15.14 (200¥/50Hz) 13, 14.74 (200¥/60lz) 7, 13.44 (220¥/60lz) 7, 7. RP3B-37 --------~ 15.14 (200V/50llz) 13, 14.74 (200¥/60Hz) 7, 13.44 (220¥/60H2) 7, 1 RP38-55 ~~ 22.0A (200V/S0Hz) 18. 21.24 (200V/60Hz) 11. 19.64 (220¥/60Hz) 11. 8 4 #24, 31. = 3A -94 9A 9A 9A 5A 4s BA, . 3A, . BA . BA TA 6A = 0A = 0A A 1A 8A 5A 4A 1A . 8A 5A 4s on 4a OA 9A 3 phase induction motor 0 on /rev {cc/rev} 8 cn®/rev (cc/rev} 4 cn*/rev {cc/rev} 7 on*/rev {co/rev} . T5KW/AP SkW/4P . 2K8/AP = THN / AP. = BR /AP (230V/50H2) 380V/50i'z) 400v/50Itz) (415¥/50Hz) (230¥/50H2) (380¥/50uz) c400v/50l2) (415V/50Hz) (230¥/502) (380¥/50Hz) 400¥/50H2) (AI5V/50Hz) (230V/50Ht2) (380V/50Hz) 400v/50H2) CA15V/50H2) (230¥/50ll2) (380¥/50lz) 400¥/50H2) (415¥/50H2) (230V/50lz) ¢380V/50Hz) 400v/50H2) (A15V/50H2) (230¥/502) (380¥/50Hz) (400v/50H2) (4150/5082) .7A 7A 7A oa 9A BA 4A = 2A 1A . 5A - 3A 4A 3k 5. 6A = AA 34 6A AN 5A 7A my Variable displacement piston pump AC 34 200V/50Hz 200V/60H2 220¥/60l2 (Refer to Nomenclature) 400¥/6011z) (440V/60H1z) 460V/60Hz) 400v/60it2) C440V/60it2) (460V/60H2) c400v/60Hz) (440V/60112) (460¥/60H2) 400V /60Hz) 440V/60112) 460V/60H2) 400v/601I2) (440V/60H2) (460V/602) 400V/60H2) (440V/60Hz) (460¥/60Hz) (400v/6012) (adov/60H2) 460¥/60112) SE-3146/\Maximum allowable working pressure RPO8-07 ~ 18. 7MPa { 140kgf/ca*} RPIS-15 13. Pa { 140kgf/cn*} RPI5-22, -------- 20. 6MPa { 21 0kgf/cm?} RP23-22 -------- 13. 7MPa { 140kgf/cm?} RP23-37 -------- 20. 6MPa ( 210kgf/cn?} RP38-37 -- 13. 7HPa ( 140kgf/ca*} RP37-55 ~~ 20.6MPa ( 210kef/cn?} Hydraulic output power range -- Refer to Clause 9.2 ~ Pressure compensator control (PC Control) Hydraulic control ~~ Suction port size RPO8-07 ~ ~ Flange connection (4)M10bolts (Plange:JIS B2291 SHA15) RPIS Flange connection (4)M10bol ts (Plange:JIS B2291 $SB20) RP23, 38 --------- Flange connection (4)M10bol ts (Plange:SAE J518 1 1/4" split flqange) Discharge port size RPOB. 15 Tapered thread Re 3/8" Cinch) RP23, 38-— Tapered thread Re 3/4” Cinch) Drain port size RPOB, 15: ---- Tapered thread Re 3/8” (inch) RP23, 38-~ ~ Tapered thread Re 1/2" Cinch) se-3146A\Mineral base oil R&O/Anti vear oil 180 VG 32 ~ 68 - 15 ~ 400 mm®/s {cSt} M@ lydraulic oil ~ + Viscosity grade - + Viscosity range - + Oil temperature range in reservoir ----- 0 ~60 + Water content ~ - Less than 0.1 vol% + Contaminant level - ~ Less than NAS 9 class Precautions + Use mineral base oi] as hydraulic (fluid) oil. Use of other hydraulic oil (water contained/synthetic base) is not allowed because it results in short-circuiting and leakage. HM Allovable inlet absolute pressure 84~300 kPa {0.83~3 kgf/cm") Maximum case pressure O.1 MPa {1 kgf/cm?) Oil volune in case RPO8-07- 1100em® {ce} RPIS~15~ 2300cm* {cc} RP15-22 2300cm* (cc) RP23-22- -- 4500em" {cc} RP23-37---~ 4000cn* {cc} RP38-37- 4000cm? (cc) RP38-55- 3500cm* (cc) Protection ~- 154 Insulation class --- E-class Ambient condi tions-~ Atmospheric + Temperature : 20 ~ 40°C + Humidity 20 ~ 95% + Altitude - up to 4000 Mass RPOS-07 35 ke RPL5-15 55 kg RPI5-22 55 kg RP23-22 67 kg RP23-37 73 ke RP38-37, 73 kg RP38-55 87 kg 1- SE-3144. Structure and Function ( Refer to Section 10-1 Structural Drawings) 4-1 Structure © Rotor punp body is composed of a housing(41) and a front cover(31), The terminal board(4) for power supply is attached to the housing and a pressure compensator control valve(11) to the front cover respectively. © Motor stator(36) is fixed to the inner housing and motor rotor(38-1) and cylinder block(38-2) interference-fitted in it are retained at the rotor center by shaft(37). This shaft is supported in free rotation with the bearing units(43) in the housing and the front cover. © The cylinder block assembly composed of piston assembly(35), retainer(45), spring(38-5), etc. acts as a pump. © Variable swash plate(34) intended to control the piston reciprocating stroke is built in between the piston head side of the cylinder block assembly and the front cover. At the counterside of the cylinder block assembly, valve plate(39) action as the rotary sliding surface of the cylinder block is fixed to the housing. © The variable swash plate unit is composed of swash plate and bias piston (4D, control piston(55), spring(49), etc. to control the swash plate angle. ‘The swash plate can snoothly s¥ash on the journal bearing(58) of swash plate holder vhich is housed in the front cover. ° ‘The valve plate distributes oil in the piston bore of the cylinder block to the suction port and discharge port which are both opened to the housing. sp-3146A\4-2 Function © The rotor and the cylinder block kit are rotated by the motor and Simultaneously pistons inside the cylinder block reciprocate along the swash plate, © This reciprocal motion results in volumetric displacement of the piston bore, whereby continuous sucking and discharging are effected. © The volumetric displacement in the piston bore varies with each swash angle of the swash plate. Hence, the discharge rate can be increased/reduced by adjusting and setting the swash angle to an intended degree. ( Refer to Subsection 10-3 * Adjustment of Di Rate” .) harge 4-8 Pressure Compensator Control ( Abbreviated as * PC Control” ) © Usually the stash plate is kept at the preset maxiaum swash degree by bias pistons with spring into which discharge pressure is supplied. and oi1 volume equivalent to this swash plate angle is discharged, Ces { a B c 2 D 8 : E PC set pressure Discharge pressure ——~p Fig.l SE-3146f4\© The discharge pressure is partly induced into the spool end face of the PC control valve. When the pressure is further raised up to nearly the adjusted and set pressure ( PC set pressure ) by means of a spring internally provided in the PC valve(Fig. 1, C ), the spool is shifted due to the pressure rise, then permitting the oil discharged to be reduced. The reduced pressure is fed as control pressure into the control piston. ( Pig. 2) Spool Spring PC valve body Pressure adjust screw L= prain line Nock nut ‘= Control piston (Control pressure) Discharged oi! (partly) Fig. 2 © Due to action of the control pressure, the control piston makes the swash plate angle smaller against the bias piston and the spring and thereby reduces the discharge rate. In this case, the discharge pressure, control pressure and discharge rate are balanced automatically and stably. (Fig. 1: C+D —>E) © When the discharge pressure has reached the PC set pressure, the swash plate angle is nearly 0° ( neutral position ) and the discharge rate cones down to zero, with the discharge pressure kept at the PC set pressure. Such a condition is called “Dead lead” or ~ Full Cut-off In this case, the swash plate is in slight tilt corresponding to the replenishment rate against drain. ( Fig. 1: E ) se-3146A\© If the discharge pressure comes down slightly from this dead head condition the control pressure supplied into the control piston reduces correspondingly so that the swash plate is pushed toward the maximum swash angle by the bias piston with spring and then permits increasing of the discharge rate. ( Pig. 1: E> D—>C) © When the discharge pressure further cones dovn with discharging, the control piston pressure is released into the drain line so that the swash plate return to the initially preset maximum swash angle and the discharge rate is restored. ( Fig. 1: € > B, A) © Further, the pressure compensation control system can stably hold pressure and flow rate at optional points A to £ in Fig. 1. However, continuous operation is not available in the area beyond motor capacity. Furthermore, even under step operating condition like A> B and A= E in Fig. 1, the discharge pressure passes through C-point instantaneously. In this C-point exceeds greatly the motor capacity, further continued operation will be occasionally unavailable. ( Refer to Subsection 9-2 "Output Range”. ) SE-3146A\5. Installation, Piping and Wiring 5-1 Installation and Piping S11 ° Installation When carrying the Rotor Punp individual to the installation site, lift it using the eye bolts ( 2 pcs. ) after attaching them to the upper body. In handling, be careful not to give strong impact to it. Install the pump, with its case drain inlet plug upside and vibration absorbing rubber downside. Tighten four foot bolts after complete levelling of the pump body. ‘The size and tightening force of these bolts are as follows: RPOS8 RP15, 23, 38 Thread Tightening force for tightening Bolts | M8, Depth 16 om M10, Depth 20 om ° ° Precautions = Before lifting, be sure to check that each eye-bolt is comple tely screwed in the body and apply two-rope lifting. Inconplete screwing-in or one-rope lifting will possibly cause drop accident, Two eye bolts attached to the body are just for lifting use. Avoid lifting the pump body together with tank base, ect. by using these eye botls after the installation, Otherwise, the weights of the tank base, etc. will act on the vibration absorbing rubber between the body and the foot, then causing danage or drop accident. The surface temperature of the pump body rises occasionally up to around 80 °C while the Rotor Pump is running. Therefore, keep a sufficient space around it and also don’ t leave other material in contact with it. For protection against contact with hot surface of the pump body, proper cover should be fitted. 12 27-34Nem (277-346kef+cm) | 53-67Nem (544-680kefrcm } | SE~3146f\Precautions = O The fixture provided between the body and the foot is intended to facilitate piping work and to protect the vibration i absorbing rubber as well. Keep the fixture as altached until start of test run. Further, vhen it is forecast that rubber vibration of wide amplitude acts on the vibration absorbing rubber due to transportation and repiping, even after installation of the pump body, re-attach the fixture to Protect the rubber, One bolt and two washers (Both side) SE-3146/\5-1-2 Piping 5-1-2-1 Suction line © Install the suction pipeline so that the inlet absolute pressure at the suction port is maintained fron 84 to 300 kPa (0.83~3 kef/en?)) . Suction pressure exceeding this permissible limit or inclusion of air in the of] will occasionally result in abnormal noise and vibration. Therefore, the piping vork should be performed with good attention to the following items. (1) Select joint specification and pipe size conforming to the above requirement. (2) Avoid use of a bend and make the suction pipe within 2m, (3) Keep each joint part perfectly airtight. (4) Keep the height of the suction port within I m from the oil level in tank. (5) When installing the body above the oil level in tank, don’t install the suction pipe above the suction port level. This is to prevent air pocket inside the pipeline. RPOB RP15, 23, 38 ‘Thread for tightening Bolts | M8, Depth 16 mm M10, Depth 20 aa Tightening force 27-34N-m (277-346kef cm) | §3-67Nem (544-680kuf +cm ) ee! [Suction port © Apply a 150-mesh suction filter to the suction Line. ~ 14 - se-3146fA\5-1-2-2 Discharge line © Even in discharge piping work, pay attention to the above items (1) to (8). Furthermore, apply a line filter (25 micron max. ) to the return line to tank. © In order to prevent abnormal pressure rise to check system pressure, install the relief valve and pressure guage in discharge line. © In case of punp failure, if the return flow volume from discharge line to suction line exceeds stank capaciy, install check valve in discharge Line. RPO8, 15 RP23, Port size Re 3/8" Cinch) Re 3/4” inch) Tightening force Pressure capability 59N-m (600kgf-cm) Nax. pressure x 1.5 MPa Seal material Discharge port Polytetrafluoroethylene (PTFE) SE~3146/\ 98N-m (1000kgf-cm)5. -3 Drain line © In drain piping work, pay attention to the following itens in addition to the above items (1) to (3) (6) Locate the return line to tank below the oil level and remote it as far as possible from the opening of the suction line. (D Install the drain Line in independent form, without covering with other return line, so that the case internal pressure is maintained al O.1 MPa (1 kgf/cnt } max., with reference to the table below. : roe | RP23, 38 i Pipe size © |a/8" Goside dia. 68.5 im) | 172" inside dia. 610.8 min.) Inside dia. of pive | €12 ain ; 15 min, Pipe length | Im max. i Tightening force | 58N-m (B00kgr+cn) 9BN-m (100k *cm) : Drain port fi “Precautions © Rotor Pump is provided with a vibration absorbing rubber as a standard between its body and foot, which is intended to damp i structural transfer noise arising from vibration transfer in i i order to enable the punp to effectively fulfill the low noise Tunning as one of its features. Due to this reason, each pipe- line is required to have flexibility. © Inflexible steel pipe "ill possibly cause not only increase of noise level and vibration amplitude but also oil leak or danage the pipeline. To avoid such a possible trouble, apply (at least partially) flexible piping (e.g. hose ) so as not to give jormal piping load to the punp body. eigee sE-3146A\5-2 Oil Filling into Pump llousing © Before starting the Rotor Pump, remove the case drain inlet plug from the housing top and then feed specific hydraulic oil( fluid oil ) into the housing up to full level, through the case drain inlet port. After that, restore (the case drain inlet plug. The oil volume to be fed is listed in page 7. Case drain inlet port wutions = © Never run pump without oil filled to prevent the internal component from severe danage, © Use mineral base oil as hydraulic ( fluid ) oil. Use of other hydraulic oi1 ( water-contained/synthetic base ) is not allowed because it results in short-circuiling and leakage. 5-3 Wiring O Add circuit breaker to the main pover line to protect the electric circuit from over-current ( short-circuit, ete. ) and the motor from overload. In addition, provide a earth leakage breaker [5aA). (Refer to motor rated current in Page 5) O Mler renoving the cover of the terminal box hich is attached to the Side face of the Rotor Pump, guide the cable through the wiring port of the terminal box. In this case, use a conduit, etc. suitable to the wiring port size ( 23mm dia. for RPO8 to RP38-37 and 27mm dia. for RP38-55 ). -11- se-31464\EARTHING TERMINAL © Connect the cable to the terminal block as illustrated in Fig. 3. For wiring connection, use a solderless terminal of proper size and tighten the M5 screw with specific tightening torque so as to prevent inter-phase short-circuiting and leakage into the housing. Further, don’ t apply any tension to the connections. V-PHASE W-PHASE U-PHASE U,V, W-PHASE, EARTH TERMINAL. Thread size M5 ws Tightening force (cNem) 300 - 400 300 - 400 © After the wiring connection, securely restore the terminal box cover. Warning © Improper electric wiring non-conforming to the instructions given in 5-3 will cause not only functional failure and trouble of the Rotor Pump but also dangerous accident. Therefore, electric wiring work must carefully be performed in compliance with the instructions given in this Subsection. ears SE-3146f\6. Test Run © Be sure to check that the hydraulic circuit and the electric circuit including the Rotor Punp are all ready for operation start. Put the hydraulic circuit in unload condition. In addition, check the cylinder actuator, ete. for normal functioning and safety. © Renove the fixture which is provided between the Roter Pump body (housing ) and the foot. Store the renoved fixture and reuse it to protect the vibration absorbing rubber vhen moving the Rotor Pump to other place or perforning repiping work. O Set the length of discharge adjust screw provided on the front cover of the Rotor Pump more than 2/3Qmax. In case of small discharge rate, the sucking performance at starting may occasionally become inadequate. ( Refer to Subsection 10-3 Adjustment of Discharge Rate”. ) Discharge Adjust Screw ~ Front Cover __ {= Precautions = © To prevent oil leakage from the threaded portion, keep the minimum extruding screw length from the front cover surface. (Refer to 10-3. Ajustment of discharge flor) : © The minimum PC setting pressure is 1.5 MPa, and corresponding to extruding length is. 13mm, - 19 - sE-3146f4\© Loosening too much the pressure adjust screw of the pressure compensator control valve will result in oil leakage from the threaded portion or cause the pressure adjust screw and the valve internal component(s) to dangerously cone out together with oil. Therefore, keep the extruding screw length fron PC valve body within 19.5 mm. PC valve body Pressure adjust © The adjust screw is mechanically stopped by the valve body. ‘Therefore the setting pressure of PC valve does not exceed Maximum setting presuure x 1.25 MPa. © For adjustment of the PC set pressure, refer to Subsection 10-4 Adjustment of Discharge Pressure”. 6-1 Flushing Operation © Apply flushing operation to the Rotor Punp for complete removal of harmful contaninants which renain inside the pipelines and the tank after assembly of the hydraulic circuit. @ Start the Rotor Pump in inching mode by repeating several cycles of power switch ON-OFF operation, At the same tine, be sure to confirm norm rise of the outlet pressure. In the case of putting the Roter Pump in initial operation, it takes a little more tine for pressure rise due to air existing in the hydraulic circuit However, when the pressure fails to rise even after § minutes and over from punp start, check the wiring because the possible cause is reverse rotation of the motor due to wrong wiring connection to the notor. (Refer to Subsection 5-3 "Electric Wiring”, (Fig. 3).) Ee SE-3146 j@ Existence of air in the hydraulic circuit, if any, will result in abnormal noise and vibration or unstable functioning of the actuator. To avoid such troubles, completely purge air out of the hydraulic circuit by inching as discribed above item @. @ After ihching for sevral cycles, let the ROTOR PUMP run about 2 to 3 hours, with the circuit pressure kept at low value (1 to 1.5 MPa { 10 to I5kgf/cn? }). During this flushing operation, be sure to check that no oil leaks from the pipeline, ete. ® After the flushing operation, completely drain hydraulic oil out of the tank and refill fresh hydraulic oil. At the same time, clean or replace both the line filter and the suction filter with new ones, if clogged and contaminated. 6-2 Operation © For the pump operation, follow the flushing operation sequence. © For the operating conditions. comply with the requirements and conditions given in Section 3 * Specifications and Operating Conditions cautions = © Occasionally the surface temperature of the pump casing rises up to about 80 °C while the Rotor Pump is running. This is not abnormal rise, © Operating the Rotor Punp beyond the specified operation range vill cause the punp not to fulfill its specific perforsance or result in operation failure and trouble of the pump. a1 - se-31464\7. Waintenance and Inspection © For maintenance and inspection of the hydraulic unit overall ( filter check, etc. ), follow the instructions given in the individual manuals for the components of Hydraulic Unit. Furthermore, maintain and control the operating conditions given in Section 3 ” Specifications and Operating Conditions © For maintenance and inspection of the Rotor Pump, conduct routine check. If sonething abnormal be found upon routine check. take proper action in reference to Section 8 ” Troubleshooting Routine check it ens @® Normal start, normal pressure rise @ No oil leakage from the pump casing @ Normal running noise ® No abnormal vibration ® Set pressure stably maintained Precautions = | © Continuous running of the pump in abnormal condition vill cause the punp and other ambient devices not to fulfill their specific performances and, in the worst case, will result in functioning failure and trouble. © For the hydraulic unit, the hydraulic ( fluid ) oil plays an important role of lubricating the internal components of each i hydraulic device, in addition to the power transmission as its main role. Hence, change the hydraulic oil evry year. 8, Storage © If the rotor pump is not used for several weeks or longer, plug or cover the inlet, outlet and drain ports to protect against dust. - 22 - SE-3146A\9. Troubleshooting Phenonenon-1 Possible caused ‘O No specific power supply into the terminal box © Energized No-Fuse Breal (1) Overcurrent across the circuit due to faulty electric wiring ( short- circuit, etc. ) (2) Overcurrent across the cireuit due to short- circuit inside the Rotor Pump. Improper operating con- ditions and breaker capacity © Energiz ikage breaker (1) Leakage caused by faulty electric wiring (2) Leakage inside the Rotor Pump : Motor fails to start. It starts, but stops immediately, Counteraction electric wiring connection so as to supply the specific power. (1) Check the electric wiring and take corrective measure not to permit overcurrent. (2) Replace the pump. (3) Apply proper operating conditions and breaker capacity. (1) Check the electric viring and take corrective action to prevent leakage. (2) Replace the pump. - 23 - © Check the pover source and the | sE-3146A\| Possible causes due to wrong wiring connection to the motor _ ae © Too high viscosity of hydraulic ( fluid |G Suction negative pre: ure exceeding perissib| © Inclusion of air in the suction line (1) Short oil level in tank and air sucked in the oil (2) Air sucking fron the suction line (3) Inclusion of air in drain pipe or return pipe due to its height above the tank : oil level a © Air renaining in the hydraulic circuit /O Pully screved-in discharge adjust screw | Discharge line hydraulic cireuit in unload or no-load _condi tion a. © Set pressure of PC valve is ___to0 GPC valve actuating failure normal wear or danage of pump internal components (© Reverse rotation of the motor — Phenonenon-2 : Motor starts, but pressure does not rise. Specific flow rate is not reached. ; : Counteraction © Chek wiring connection Check the viscosity grade and preheat it Check tie suction Tine for pipe/filter clogging 6 (1) Increase the oi! level up to specified level (2) Check each joint part. ( loose, imperfection of seals, etc. ) (3) Modify piping or increase oil level. © Purge out air. © Loosen it and increase the swash plate angle © Put it in Load condition. Further screw-in the pressure Replace PC valve Replace the pump 24 SE-3146f\Phenonenon-3 : Abnorsal noise and Possible causes high viscosi © Suction negative pressure] exceeding pernissible value Inclusion of air inathe suction line (1) Inclusion of air due to low tank oil level (2) Air sucked from the suction line (3) Inclusion of air due to drain pipe or return pipe height above tank oil © Abnormal piping load acting on Rotor Pump body © The fixture between the pump body and the foot is not _renoved. © Too high gousing internal pressure caused by resistance in the drain pipeline © Imperfect functioning of hydraulic unit component © Abnormal wear jage of punp internal components vibration Counteraction ‘iscosi ty preheat the oil for proper viscosity. Check the Suction line for pipe/filter clogging (1) Increase oil level up to specified level. (2) Check each joint part ( loose, imperfection of seals ) (3) Modify piping or increase the oil level, out air. Make the pipeline flexible. Remove the fixture. Wodify the drain pipeline to reduce the internal pressure. ‘Take proper corrective actions in accordance with the in- struction manuals for the hydraulic unit and the __Tespective hydraulic devices. © Replace the pump - 05 - SEPhenonenon-4 : Oi 1 leak from Rotor Pump Possible causes cena Damaged O-ring or g Loose of bolts/plug Too mich loosening of pressure ___adjust_ screw of PC valve © Too much tightening of discharge adjust screw 3 reaches high degree Possible causes © Too high temperature of tank [O Abnormal wear or damage of — [___puap internal compone Phenomenon 6 : Pressure compensator It functions, br Possible causes (© Too high set pressure of PC ___valve : © Air remaining in the hydraulic circuit © Over-leakage from the hydraulic circuit © Running fault or trouble of Phenomenon-5 : The surface temperature OF ROTOR Pump housing (90°C and over ) Counteraction © Lower the oi] temperature. C0 to 60% © Match the operating condition pacity. © Replace the pump control fails to function. stabl Counteraction © Loosen pressure adjust screw. © Purge out air. | 1G Take individual counterneasures against leakage. G Check the load equipment load equipment ating fai lui /O Abnormal wear or danage of (valves, cylinders etc. ) Replace. - © Replace the pump - 26 - SE-3146/\10. Reference 10-1. Parts list + a & a nya # & & a8 ee [4 fetus i] 6 [sort 2 2 | SEAL WASHER 1 [17 | recucar crrcutar wasner| 4 3 _[ NAMEPLATE 1 |" 1a ['sockeT weap pLuc 2 4 | Tearwinat eox assewaty | 1 | 49 | Puastic PLuG ie] 5 [EvE-BOLT 2 {20 [river 2 6 | vieearion-Assonsine eusoee| — 4 | D1 | NAMEPLATE 1 7_| Foor 1 | "22" ['sockeT Head PLUG 1 8 | SPRING LOCK WASHER | 4 | ~23 | SUCTION PoRT covER”] 4 ‘9 | HEXAGON NUT 4 [24 | casket 1 40['sockeT HEAD BOLT 8 | 25 | socket HEAD BOLT 2 11 [Pc VALVE ASSEMBLY 4 | 26 [caution PLATE 1 [12 [socket Head Bout 4 |" 27 [socket HEAD PLUG 1 13_[Gasker 1 | 28 [Plastic PLUG 1 14_{ SOCKET HEAD PLUG 1 [eg 15 [0 RING ee 30: Fig.4 a se-3146A\ECT ION SECTION A-A, a a z fala € & z af 31_[ FRONT cover i_| 47 [pias Piston { [32 [0 RING [48 | SPRING RETAINER 1 33_[ CONTACT PIECE 2 [49 | B1as_ SPRING 1 i [34 [swash PLATE 1 | 50_[o RING 1 : ‘35 | PISTON ASSEMBLY 9(7) [51 [tue : rt 36_| Stator 1_[ 52" [oiscwaece abiust screw | —t 37_[ SHAFT i [753 [o Ring f 38_| ROTOR ASSEMBLY a 1 39__| VALVE PLATE 1 [55 [ conTRot Piston f 40_[ Pin, 1 {56 | sockeT HEAD PLUG i 41 | HOUSING 1 | 57_['stopper 2 42_| PIN, 2 | 58 [Bear ine (JOURNAL) 2 43 | BEARING (NEEDLE) 259 [ MACHINE scREW 2 44 [SPRING PIN 1} 60 ['srrinc 1 45_| RETAINER ie 1 46 [RETAINER GUIDE 1 [62 [RETAINING RING 1 () RPO8 ONLY Fig.5 - 28 se-3146Z\NO. PARTS NAME OTY, 38-1 | noton3 rwnse moucrion HoTOR| | 38-2 | CYLINDER BLOCK 1 4 38-3 | RING RETAINER 1 1 rl 1 |_38-4 | WASHER (1) r | 38-5 | SPAIN 38-5 | WASHER (2) a z af 0 RING 1 ‘TERMINAL BOX 1 COVER 1 GASKET 1 "TERMINAL i ‘GROSS RECESSED HEAD SoREW] 4 (GROSS RECESSED HEAD SREW] 4 PLAIN WASHER 1 ‘SPRING WASHER 1 HEXAGON _NUT. 4 4 (CROSS RECESSED HEAD SCREW] SEAL WASHER WO. PARTS WAME QTV, L1=1 | PreSsinE AO.USTHENT screw 41-2 | ROCK NUT 11-3 | VALVE BODY 11-4 [0 BING. [11-5 | SPRING 11-6 [SPRING RETAINER 11=7-| SPOOL 41-8 | SOCKET HEAD BOLT 11-9 T0 RING 41-10 TO RING: PEER E Fig.8 ~ 29 - SE-3146/\Table 1. O-RING LISTS NUMBER RP15 RP23/38 (Gry, 15 JIS B 2401 1- B PIA 1 T - 32 | AS 568 [ HS28775 ] 160) AS 668 ( HS28775 ] 167 |AS 568 [ MS28775 ] 173) 1 50 AS 568 ( NS28778 ] 914 1 53 JIS B 2401 1- A PB 1 JIS B 2401 1- B G45 1 JIS B 2401 1- B PI4 AS 568 [ MS28778 ] 903 JIS B 2401 1- BP6 10-2 Output Power Range ‘The following table shows the current at 200V/S0Hz and 220V/60Hz. { 220v/60n2 ‘The rotor pump is able to operate continuously up to 150 ¥ of rated current, since electric motor is cooled by hydraulic oil. The short time (within 6 seconds) operation in a duty cycle is possible up to 200 % of rated current, In both conditions, keep the oil temperature in reservior at 60 C or less. 30 - SE-3146MODEL RP15-15 RP15-22 VOLTAGE SUPLLY 200V/502 200/601 | 200v/50H2 | 220V/60H2 RATED CURRENT = 100% (A) 6. 8 5. 8 9. 6 8.4 | 150% (AD | 10. 2 8.7 144 6 | |] 13. 6 11. 6 ee a | WODEL RP23-22 RP23-37 VOLTAGE SUPLLY 200v/s0H2 | 220v/60H | 200V/50%2 220¥/60H2 RATED CURRENT = 10096 (A) eee 15.1 13.4 | 15 0% (A) 13.1 22.7 20.1 200% ay | 20.0 i 17.4 30. 2 26.8 WODEL RP38-37 RP38-55 VOLTAGE SUPLLY 200v/s0n2 | 220¥/80H2 | 200V/50H2 220¥/60He RATED CURRENT = 100% (A) | 15. 1 18.4 | 22.0 6 150% (A) | 22.7 20.1 33.0 4 a] ao. Lee 44.0 2 31 - SE-3146f\15 T \ 50% 10 t 200% Qs —| Umin 100% oO 0 6.9 13.7 {70} (140) P > MPa{ kgl/om2} RPO 8-07 (220V/60lIz) Fig.9 T 30, - | 150% 25 : 25| 1 150h%. aN 20 2p0% 209% \ 15 | 15] 10 Q ig 100% Umin | 100% | oe 5 : °o 69 cal 208 | ; : : ° : ; ee ee wor (ia) Bay P MPa(kgl/cm2) P mpa(kgl/om2) RP15-15 (220v/60lz) RP15~22 (220v/60HI2) Fig.10 Fig.1 - 32 SE-3146f\= 7 150° : 40} 160% 40 ad aN . 20b% 20 200%} Q 7 Q ‘ 100% ‘Umin 49 100% Umin 10 : Bay . 0 69 13.7 20.6 0 69 13.7 20.6 {70} {140} (210) {70} (140) (210) P MPa(kgliem2) P MPa (kgt/em2 ) RP 23-22 (220v/60lIz) RP23~-37 (220V/60llz) Fig.12 Fig.13 oo {1004 . it i ' 4o | 40 200% 100% Q 59 Qf NE Umin 100% Umin | . SS 6.9 13,7 20.6 ° fo (aa) ea (70) (140) (240) P MPa (kglem2) RP 38-37 (220V/60llz) Fig.14 P MPa { kglcm2 ) RP3 8-55 (220V/60liz) Fig.15 - 93 - SE-3146/\10-3. Adjustmemt of Discharge Flow Discharge rate is adjusted by the discharge adjust screw provided on the front cover. ~ Discharge rate is decreased - Discharge rate is increased *Clockwise direction -- *Counter-clockwise direction (Note) 1. Discharge pressure is 2. 0MPa. 2. Length L is as follows. Front Cover RPOS Q (/min) Fig.16 - a4 SE-3146/\or) e zn 3 10 0 RP23-22 » L Hee — = 4 a Sale 20 10 | ° 10 L (mm) Fig.18 - 35 20 SE-3146/\Q (/min) Q(1/min) = exp ewe eo S38 &€8 ag 10 15 20 Lm) Fig.19 SE-~3146f\10-4 Adjustment of Discharge Pressure Maximum discharge pressure is limited by the setting pressure of PC control valve, and be able to adjust by the pressure adjust screw. ~ PC setting pressure is increased ~ PC setting pressure is decreased *Clockwise direction -- *Counter-clockwise direction ~ Wodel Spring No. Pressure adjusting range 1 LS ~ 6.94Pa (15~ TOkgt/ea2) RP«* 2 1.5 ~ 18.7 MPa (15~ M0kat/en2} a 3.4 ~ 20.6 MPa (35~ 210kgf/cm2} 5) 15 ~ 6.9.¥Pa (15~ TOkgt/en2) (#) Spring No.5 is only applied to RPI5A1~##-30. (kgf/cm2) (MPa) 200 19.6 2 a 8 150 14.7 » e 5 6 2 = 100 9.8 6 3 $s 2 50 4.9 5 a 6 0 0 Rotation number of the puressure adjust screw (turns) Fig.21 31 - SE-31464\