VC202/303 Repair Instructions

Please read & observe all safety warnings English version/J.Kohn

VC202/303 Repair: Index

page contents

3 Health & Safety

4 Tools Required
5-25 Disassembly
26 Pre-Assembly
27-39 Assembly
40 Final Testing

Note: Pump shown with several optional accessories (not typical)

2 September 2009
VC202/303 Repair: Health & Safety

Danger of injury if components tip over or fall off!

Loose fasteners can permit some components to only be held by their
centering, their seating or even not at all. Components could fall and cause
personal injury or equipment damage! Take appropriate precautions when
dismantling and reinstalling components

Danger of crushing injury or equipment damage

Inspect all rigging, work surfaces and lifts for safe operation prior to use

Personal Protection Equipment

Wear protective safety shoes & safety glasses at a minimum

‘Right-to-Know’ and MSDS sheets

Is the unit known to be free of any chemical or biological hazards?

3 September 2009
VC202/303 Repair: Tools required
• Hex driver wrenches: 4-6mm with
ratchet & extensions
• Open-end wrenches: 10-27mm
• Box-end wrenches: 19 & 27mm
• Small adjustable-jaw puller
• Soft-faced hammer
• Assorted standard screwdrivers
• Side-cutting pliers
Special tools required:
• M6 slotted-screwdriver, PN (part
number) 892928 (required for dowel pin lock nuts)
• Shaft seal protector, PN 935643
• Seal installer: 47x35mm
• Bushing driver: 39mm
• Loctite® 262™ Thread Locker

4 September 2009
VC202/303: Disassembly

Inspect all rigging, work surfaces and lifts

for safe operation prior to use

Drain oil into a suitable container

Remove lifting-eye bolt. Inspect
Remove & inspect oil sight glass sheet metal for damage.

5 September 2009
VC202/303: Disassembly, continued

Remove (3) screws from top and Remove sheet metal cover by
front-side of cover with 4mm hex sliding off to one side
wrench

6 September 2009
VC202/303: Disassembly, continued

View of A, or drive motor-end. View of B or non drive-end, ready

With cover removed, inspect unit for inspection
for leaks, damage or distortion

7 September 2009
VC202/303: Disassembly, con‘t

With motor safely supported, Remove motor with flange and

remove (4) hex bolts attaching fan as an assembly. Careful not
motor flange to housing cover A to damage Oil Cooling Coil tube!
with 6mm hex driver.

8 September 2009
VC202/303: Disassembly, con‘t

Pump shown with motor

assembly removed. Inspect Carefully turn pump over onto
(red) coupling insert for the oil separator housing
wear. Unusual wear
indicates a possible
alignment issue.

9 September 2009
VC202/303: Disassembly, continued

Remove suction flange by Inspect o-ring and non-return

removing (4) hex head screws valve for damage
with 6mm hex driver

10 September 2009
VC202/303: Disassembly, continued

Disconnect pipes from oil

Using appropriate open-end separator housing
wrenches, disconnect oil
pipes from covers. Inspect
each pipe for kinking or
damage or blockage.

11 September 2009
VC202/303: Disassembly, continued

Remove protective screen from Slide screen off by hand

Oil Cooler (bottom side)

12 September 2009
VC202/303: Disassembly, continued

Loosen Oil Pipe connection fitting Next loosen connection fitting and
on A side end-cover pipe from oil separator housing

13 September 2009
VC202/303: Disassembly, continued

With access now to drive-end

side, carefully inspect the four (4)
motor flange mounting pads for
burrs, cracks or damaged threads Remove coupling set-
screw with 4mm hex
wrench

14 September 2009
VC202/303: Disassembly, con‘t

Remove pump coupling with an Remove shaft key with suitable

adjustable jaw type puller pliers. Inspect shaft and keyway
slot for damage or burrs.

15 September 2009
VC202/303: Disassembly, continued

Continue disassembly by next Remove hex bolts from B-side

removing (4) hex bolts from A- cover using 6mm hex driver
side cover with 6mm hex driver

16 September 2009
VC202/303: Disassembly, continued

Loosen end-cover from its seated Carefully remove A-side cover

position by gently tapping with a from cylinder
soft-face hammer

17 September 2009
VC202/303: Disassembly, continued

Remove each of (3)

vanes from the rotor.
Note which vane was
removed from each
slot. Inspect each
vane for possible
damage or wear on
both sides of the
vane. Inspect the
running edge for
scoring

18 September 2009
VC202/303: Disassembly, continued
Check that holes are clear from
dirt and debris. Drain pump‘s
compression chamber after it is
disconnected from the oil sump
Pay special attention to
the ‘f’ clearance area of
the cylinder for wear
Check connection to oil
separator & allow oil to
drain.
19 September 2009
VC202/303 Disassembly, continued

Remove B-side cover Check cylinder areas for

with gentle prying. signs of wear and
Careful not to damage washboarding
machined surfaces!

20 September 2009
VC202/303: Disassembly, con‘t

Remove nuts securing cylinder

Carefully lift off cylinder

21 September 2009
VC202/303: Disassembly, continued

Inspect valve plate for any broken

or bent fingers (aka: reed valves)

Inspect exhaust valve

assembly complete.

22 September 2009
VC202/303: Disassembly, continued

Remove oil separator Check oil separator Check and clean oil
cover with 6mm hex interior for debris and oil separator cover
driver deposits or varnish

23 September 2009
VC202/303: Disassembly, continued

Loosen each Oil Remove each oil

Separator Element with separator element by
19mm box wrench ¼ pulling straight out
turn counterclockwise

24 September 2009
VC202/303: Disassembly, continued
Normal Oil Separator Element shown:
Exhaust oil mist coalesces and is often
visible on the outside of the element
cover as a wet area

SERVICE TIPS !!
• The amount of oil that collects on the outer element
cover is dependent on the operating vacuum level
• A pump operating outside of its range can produce a
O-Rings visible oil mist and odor. The element is typically
saturated with oil.
• Broken or missing O-Rings can produce oil mist and
odor, even when pump is at normal vacuum levels
• Deposits will collect on the inside surface of
element. Do not attempt to clean!
• Clogged Elements will increase backpressure,
reduce flow (cfm) & increases temperatures!
Make sure each new Element has both
O-Rings in place. Lube O-Rings with
pump oil before installing into housing

25 September 2009
VC202/303: Disassembly, continued

• DO NOT attempt to remove any

‘Insert’ ring from the housing unless
necessary!
• DO examine all ‘Insert’ rings for
signs of damage
• DO make sure that Insert rings are
fully seated into housing opening—
look for visible edge around rings
INSPECT ‘INSERT’ RINGS
• Never create a situation where the
and Housing for proper fit pump discharge could be blocked
or closed-off on a operating pump!

26 September 2009
VC202/303: Disassembly, end

Remove float base with Drain away separated oil back into Inspect and clean float
27mm box wrench pump assembly. Check for
debris in float base
orifice

27 September 2009
VC202/303: Pre-Assembly

Pre-Assembly

1. Clean & inspect all parts before beginning assembly. Make

sure that they are free from burrs, cracks or damage
2. Carefully remove oil seal from endcover
3. Measure both bushings (friction bearings) for excessive wear.
Compare rotorshaft O.D. and each bushing I.D. (installed)
Maximum clearance =0.104mm. Minimum clearance =0.003mm

4. Measure cylinder I.D. for possible out-of-round and correct

dimensions per 951040-000 Clearance Sheet
5. Note: If machining or honing of cylinder is required, finish to
R3z roughness 8-12 µm

28 September 2009
VC202/303: Assembly

Stop! Review Repair: Health & Safety on page 3 before proceeding

Turn cylinder in vertical

position. Lubricate new
o-ring with pump oil & Assemble end cover
install into cylinder face

29 September 2009
VC202/303: Assembly (continued)
Put cylinder upside down
and put rotor into
cylinder and its shaft into
end cover
³
Note position of vanes.
Slots in vanes follow
direction of rotation.
Larger, rounded edge
contacts cylinder
surface.
30 September 2009
VC202/303: Assembly (continued)

Seal Protector Sleeve

Install new shaft seal

into cover with 47mm
driver. Reassemble A-
side cover using sleeve
to protect shaft seal lip

31 September 2009
VC202/303: Assembly (continued)

Feed (2) feeler tapes between the

rotor and cylinder through the
exhaust holes on both ends of
cylinder. Note: Turn the rotor by
hand as you feed in the feeler
tapes.
With both endcovers in position, apply
threadlocker to dowel pin threads. Tighten
the slotted nuts with the Slotted Screwdriver
and remove both feeler tapes.

32 September 2009
VC202/303: Assembly (continued)

Position top-side (f clearance) of Assemble valve plate. Check that

cylinder in the upright position. Feeler all holes are covered by each of
tapes should now move in and out the valve fingers
freely

33 September 2009
VC202/303: Assembly (continued)

Finish installing the valve assembly

Install gasket and assemble

end cover onto housing with
6mm hex driver. Tighten
screws evenly, starting from
middle of cover outward

34 September 2009
VC202/303: Assembly, con‘t

Using a straight bladed

screwdriver, remove the Gas
Ballast Valve’s black plastic
cover. Inspect the filter
Install float into base. element for contamination.
Screw assembly up into Unscrew ballast housing
position inside the oil making sure holes are clear
separator housing. Do from dirt and debris. Install
not overtighten! new filter element.

35 September 2009
VC202/303: Assembly, con‘t

Tighten cylinder to oil separator

housing nuts using 13mm open
end wrench.
Install new oiled o-ring.
Lower cylinder assembly
onto oil separator
housing. Take care not
to damage o-ring or
threaded studs
36 September 2009
VC202/303: Assembly, continued

Position Oil Cooler assembly and Next tighten connection fitting and
tighten connection fitting on A side pipe to oil separator housing
end-cover

37 September 2009
VC202/303: Assembly continued
Place Oil Cooler assembly
onto pump. Note: the ends of
the cooling coil pipe Insulator
are of different heights. The
smaller end points toward the
end cover B
Use a bent piece of flat steel
to gently open a space to
install the Insulator. See next
step.
Steel angle is made by
bending flat steel of 4 mm
thickness and 12 mm width
in a 90° angle. The working
length approx. 180 mm
38 September 2009
VC202/303: Assembly continued

Re-check all oil pipes Reinstall protective mesh grid

connections for tightness. Do not
overtighten!

39 September 2009
VC202/303: Assembly continued
Install new non-return valve and
oiled o-ring
Squirt a liberal amount of Now assemble non-return valve
oil into the pump inlet to to cylinder
provide initial vane
sealing & lubrication.
Rotate rotor shaft by
hand in the correct
direction to ensure good
coverage
40 September 2009
VC202/303: Assembly, con‘t

Safely lift motor with flange and fan coupling. Finish assembly by installing
Assemble to A end-cover and tighten with (4) hex black sheet metal cover onto
head screws. Make sure that the two coupling pump. Reinstall (3) screws
halves are aligned to mate—do not force! Rotate
fan if necessary. Make sure the flange is seated
squarely on each of the (4) mounting ears
Caution!! Ensure that Oil Pipes cannot contact
rotating Fan assembly

41 September 2009
VC202/303: Assembly (end)

Assembly finished, ready to add

new oil and begin testing!

42 September 2009
VC202/303: Final Testing

Warning: Before commencing start-up and testing:

Make sure you are familiar with the Operating
Manual.
Review warnings on Page 3 of this instruction. Use
caution connecting electric power to the motor.
Pump and motor generate heat that can cause
burns. Wear protective equipment.

43 September 2009