INSTALLATION and

MAINTENANCE

Universal Disc Brake

Hydraulic Power Unit

REFERENCE REFERENCE DESCRIPTION

This document contains proprietary and confidential information

which is the property of National Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV. National Oilwell Varco
Reproduction, in whole or in part, or use of this design or
distribution of this information to others is not permitted without the RIG SOLUTIONS
express written consent of NOV. This document is to be returned to 12950 West Little York
NOV upon request or upon completion of the use for which it was Houston, TX 77041
loaned. This document and the information contained and
represented herein is the copyrighted property of NOV.
© National Oilwell Varco

DOCUMENT NUMBER REV

EPL-1336 04

www.nov.com

D811000461-GEN-001/01
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REVISION HISTORY

04 10/07/2008 Added Model Drawings AM LDS LDS

03 24/03/2005 Updated Logo BKF
02 22/02/2005 Updated Template BKF
01 01/07/2000 First Issue LDS
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change Description

01 First issue
02 Updated to electronic format from PDF to MSWord in new template.
03 Updated logo
04 Added information for different models of HPU.

www.nov.com

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Preface
National Oilwell Varco is a worldwide leader in the design, manufacture and sale of
comprehensive systems and components used in oil and gas drilling and production, as
well as in providing supply chain integration services to the upstream oil and gas
industry.

This Installation and Maintenance Manual provides necessary information for

installation and maintenance of the Universal Disc Brake Hydraulic Power Unit. In order
to find particular information, just search for the applicable section as listed in the table
of contents. However, changes in the equipment may occur. Therefore, we reserve the
right to introduce amendments in the manual, as we deem necessary without notice or
obligations.

Before starting the installation and/or maintenance, the manual must be read and
thoroughly understood in all respects. All involved personnel shall read and
acknowledge the safety precautions that are stated in section 1.1.

The content in this manual is subject to change without notice or obligation.

Therefore, information contained herein should always be confirmed with
National Oilwell Varco or its representatives.

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Table of Contents
1. GENERAL…............................................................................................ 5
1.1 Safety precautions……………………………………………………….. 5
1.2 Operating principle……………………………………………………….. 7
2. TECHINCAL DATA……………………………………………………… 8
2.1 Operating conditions…………………………………………………….. 8
2.2 Cooling water……………………………………………………………... 8
2.3 Requirements for hydraulic fluid cleanliness………………………….. 9
2.4 Choice of hydraulic fluid…………………………………………………. 9
2.5 Power unit monitoring……………………………………………………. 10
3. HANDLING OF THE PACKED POWER UNIT……………………….. 11
3.1 Storage of the packed power unit………………………………………. 11
3.2 Lifting the packed power unit……………………………………………. 11
4. INSTALLATION…………………………………………………………... 12
4.1 Installation directions……………………………………………………… 12
4.2 Lifting methods and weights……………………………………………… 13
4.3 Positioning the power unit………………………………………………… 14
4.4 Mounting of cabinet feet………………………………………………….. 14
4.5 Electric connections………………………………………………………. 15
4.6 Pipe work…………………………………………………………………... 15
5. COMMISSIONING………………………………………………………… 16
5.1 Prior to commissioning…………………………………………………… 16
5.2 Filling up system with hydraulic fluid……………………………………. 17
5.3 Initial start-up procedure…………………………………………………. 18
6. CORRECTIVE MAINTENANCE………………………………………… 19
6.1 Trouble shooting…………………………………………………………… 19
6.2 Pump setting and adjustments…………………………………………… 21
6.3 VPV Vane pump repair parts…………………………………………….. 22
6.4 Vane tip orientation……………………………………………………….. 24
6.5 Oilgear Type “PVM” open loop pumps………………………………….. 25
6.6 Air back-up pump service and overhaul instructions………………….. 28
6.7 HPU Detail…………………………………………………………………. 34
6.8 Recommended Spares and Service Parts……………………………… 37
6.9 Recommended Service Intervals………………………………………… 38
7. TECHNICAL DOCUMENTATION………………………………………. 38
7.1 Power requirements………………………………………………………. 38
7.2 Cooling Water……………………………………………………………… 38
7.3 Air Supply…………………………………………………………………... 38
7.4 Pressure settings for operating National 1625 UDB Drawworks…….. 38
7.5 Hydraulic Schematic………………………………………………………. 39
7.6 Electrical Schematic……………………………………………………….. 41
8. Design Phases..……………………………………………………………. 41
8.1 Phase I………………………………………………………………………. 41
8.2 Phase II……………………………………………………………………… 41
8.3 Phase III……………………………………………………………………... 41
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1. GENERAL

1.1 Safety precautions

It is of extreme importance that the safety precautions are always followed. If you
are unsure about anything, please contact your nearest National Oilwell Varco
representative for advice.

Warning signs
In this manual, you will find the following signs, which indicate a potential hazard,
that can or will cause personal injury or substantial property damage. There are
three levels of hazard classification:

General
Limit access to the equipment only to authorized personnel. Perform measures on the
HPU only when you are completely familiar with the function of the power unit (including
the control system) as well as the complete system.

Service and repair of the electrical, hydraulic, and the mechanical functions require
professional service personnel who are aware of risks involved.Safety equipment
necessary for the prevention of accidents during the mounting and maintenance must
be used in accordance with the regulations prevailing in the local authority.
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Prior to troubleshooting
• Use the National Oilwell Varco part number and other attached technical
documentation to identify the features of your unique power unit.
• Read the attached technical documentation (this manual included) and make
yourself familiar with the HPU and complete control system.
• Use safety equipment such as hard hat, protective goggles, safety shoes, and
hearing protection.
• Always ensure that there is no accumulated energy in the system prior to
maintenance.
• Ensure that all electric power is turned off and locked out.
• Ensure that there is no entrapped pressure in the hydraulic system.
• Ensure that no pressure will enter the system in the power unit via Emergency
Calipers, stored in the accumulators.
• Ensure that all accumulators are discharged.

Electricity supply
Safety equipment necessary for the prevention of accidents must be provided in
accordance with the regulations prevailing local authority.

All electrical supply levels shall be within limits that the equipment is constructed for,
see technical documentation and maximum rating plates.

Mounting
Carefully follow the instructions and be aware of the large weights and forces involved
during lifting. Incorrect mounting and setting of electrical, hydraulic and the mechanical
components can cause personal injury or property damage.

Before starting up
Before starting up new, rebuilt or serviced equipment, all accessories and safety
arrangement functions need to be checked and tested.

Maintenance and service

Follow the maintenance intervals for your specific HPU or the maximum intervals on the
maintenance chart (section 5.2 “Maintenance Chart”) and keep a maintenance log.
Regular and correct maintenance is necessary for the reliable and safe operation.

Only use spare parts recommended and supplied by National Oilwell Varco.

Hydraulic fluid
Be aware that most hydraulic fluids can cause personal injury and severe damage to
the environment. Check the caution sign on the container or consult the supplier. Used
hydraulic fluid can contain noxious contaminates. We recommend using the service of a
professional oil company for supply and disposal of used fluids. Never dump hydraulic
fluid where it can contaminate the environment.
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Hot surfaces
Temperatures in the hydraulic system above 130° F will create hot surfaces

Emergency situations
Emergency shutdown: It has to be possible to turn off the electric power during an
emergency situation. Only use a fire extinguisher that is approved for use on both oil
products and electrical equipment.

1.2 Operating principle

Main components
1. Hydraulic pump
2. Drain valve
3. Sight glass
4. System pressure gauge
5. Air pump supply pressure gauge
6. DS & ODS service caliper pressure gauge
7. Port #11 pressure gauge
8. Air breather
9. Return filters
10. Electric motor
11. Suction filter
12. Oil cooler
13. Starter-annunciator panel
14. Level switches
15. Temperature switches
16. Air back-up pump
17. Air driven fill pump
18. Accumulators
19. High pressure filter
20. Air filter/regulator
21. Water modulating valve
22. System relief valve
23. Pressure reducing valve

Function
The function of the Universal Disc Brake Hydraulic Power Unit is to provide hydraulic
pressure to operate the Disc Brake Service Calipers, and Emergency Calipers. The
UDBHPU has four hydraulic pumps:
1. Main hydraulic pump
2. Air back-up pump
3. Cooling loop pump
4. Air driven fill pump

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The UDBHPU has several control valves:

1. System relief valve
2. Pressure reducing valve
3. Emergency caliper release valve
4. Crown-O-matic interface valve
5. Water modulating valve
6. Cooling loop pressure control valve
7. Air driven pump speed control valve
8. Air back-up pump regulator valve
9. Air supply shut-off valve
10. Reservoir drain valve
11. Accumulator bleed valves

2. TECHNICAL DATA

2.1 Operating conditions

The standard HPU is designed for the conditions listed below. If the requirements are
outside of these conditions listed below, contact your National Oilwell Varco
representative with your specific requirements for special design considerations.

Ambient temperature: SEE recommended hydraulic oils

2.2 Cooling water

The cooling system is primarily designed to operate with clean water.

When there are particles in the water, larger than 0.02 in. (0.5 mm), a water filter must
be used.

It is important to:
• Maintain the water filter clean all the time in order to get the required flow of water
through the water oil cooler.
• Ensure you have the required flow, pressure and temperature of the cooling water
(see attached technical documentation).
• Check the temperature in the hydraulic system, according to the maintenance
intervals on the chart.
• Clean the cooling system if the temperature in the hydraulic system is above the
specified limits.
• Clean and empty the cooling system (waterside) before periods of inactivity
(especially if the cooling water is not totally clean).

IF THE COOLING CAPACITY IS TOO LOW, THE SERVICE LIFE OF COMPONENTS

IN THE POWER UNIT, AND THE HYDRAULIC FLUID WILL BE REDUCED.

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2.3 Requirements for the hydraulic fluid cleanliness

The HPU is equipped with filters on the return, suction, fill, cooling loop, and discharge
lines. In order to obtain rated service life it is important to follow recommendations
concerning cleanliness levels and maintenance requirements.

Cleanliness recommendations
• The system must be flushed before start-up (section 4.12 “Flushing before start-up”).
• When filling the reservoir with hydraulic fluid it is mandatory to use the fill system
included with the HPU.
• The particle contamination level in the system should not exceed ISO/DIS 4406
16/13 (NAS 1638, class 7).
• The water content shall be <0.1%
• Always use filter elements that are supplied by National Oilwell Varco.
• The hydraulic fluid should be analyzed according to the special maintenance chart
(section 5.2 “Maintenance Chart”). You should be particularly careful when removing
equipment for repairs or maintenance so that dirt cannot enter the system.
Components should be cleaned and free of dirt prior to disassembly.

DO NOT USE HYDRAULIC FLUID THAT HAS LEAKED OUT.

2.4 Choice of hydraulic fluid

The power unit is primarily designed to operate on conventional petroleum based

hydraulic fluids. National Oilwell Varco only approves specific hydraulic fluids to be used
in the Universal Disc Brake System. Substituting any other types of hydraulic fluid will
void all warranties, and can create a hazard to personnel and equipment.

The following chart will help in the choice of hydraulic fluid for the HPU.

Table 2.4-1 Recommended hydraulic oils

NATIONAL OILWELL VARCO RECOMMENDED AW GRADE HYDRAULIC FLUIDS

Max SSU 2000 OR 500 cST

Min SSU 65 OR 13 cST

FROM :
14 deg F up to 150 deg F use ISO 22
22 deg F up to 150 deg F use ISO 32
39 deg F up to 172 deg F use ISO 46
50 deg F up to 190 deg F use ISO 58
Where ambient temperature is 55 deg C or higher use ISO 100

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Fig 2.4-1 Oil viscosity vs. temperature

2.5 Power unit monitoring

If the monitoring function is not included in the control system supplied with the HPU,
the following functions must be fulfilled in the system.

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The monitoring of the HPU switches are grouped into two levels according to the above
logic diagram.

The warning or “alarm” indication is to inform about a problem in the HPU that needs to
be addressed.

The “shut down” indication is to inform about HPU shut down. When this happens the
brakes on the drawworks will lock on. The brakes on the draworks will not release until
the problem is resolved.

The alarm horn can be silenced. However, the strobe lamp and individual indicating
lamps will remain illuminated until problem is corrected.

3. HANDLING OF THE PACKED HPU

3.1 Storage of the packed power unit

At delivery the hydraulic components are protected internally by an oil film (containing
rust preventing additives. This provides sufficient protection for indoor storage in air
conditioned premises for up to 12 months.

The HPU and included parts should be stored indoors, in dry, vibration and dust free
conditions. The HPU and its afferent parts should not be stored for more than three
months in non-air conditioned premises. (That also includes parts belonging to the
power unit that are delivered separately).

Place power unit where it will not be exposed to direct sunlight or extreme cold to avoid
condensation.

IF STORAGE TIME EXCEEDS THE ABOVE-MENTIONED LIMITS, THEN THE

POWER UNIT MUST BE OPERATED SO THAT THE HYDRAULIC SYSTEM IS
LUBRICATED WITH NEW FLUID.

3.2 Lifting the packed power unit

The packed power unit is labeled with a center of gravity and weight. Normally the
power unit package is designed for forklift truck handling.

• Center of gravity is high, see label on the power unit

• Avoid rapid acceleration, deceleration and turns while moving the equipment
• Position the forks according to the instructions below

Lifting with fork lift

• The absolute minimum fork length is 48 in.
• The minimum distance between the forks is 31.5 in.
• Position forks with regards to the center of gravity
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Parts that are delivered separately

The package is always labeled with the weight.
• Packages on shipping skids are designed for forklift truck handling only.
• Some other packages may be lifted with a lifting crane. Always check the label on
the package
• Do not stand underneath hanging load.
• Use only lifting equipment adapted to the weight on the label of
the package.

4. INSTALLATION

4.1 Installation directions

Follow these installation instructions in order for the HPU unit to work properly. The
conditions the power unit will operate in must be taken into consideration.

Improper installation, not following the instructions in this manual and in the attached
technical documentation, may affect the function and/or the service life of the power
unit. It is important that the safety precautions mentioned in this manual are always
followed.

FOR AIR CIRCULATION REQUIREMENTS, NEVER PLACE THE POWER UNIT

DIRECTLY AGAINST A WALL OR SIMILAR OBSTRUCTION. IF THIS IS THE CASE
THEN CONTACT YOUR NATIONAL OILWELL VARCO REPRESETATIVE.

Fig 4.1-1 Cabinet overall dimensions

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Placing the power unit

Take into consideration the following when placing the HPU

• Try to locate HPU as close to the Drawworks as possible.

• Minimize piping runs.
• Ensure proper ventilation for cooling purposes.
• For service purposes ensure ample room around the unit.
• Always locate HPU on the same level with the Drawworks.

4.2 Lifting methods and weight

Lifting with ropes/or chains
Ensure lifting ropes and chains are rated for the weight of HPU. Max weight is 2,000 lbs.
Maximum lifting angle is 90°.

• Do not stand underneath a hanging load

• Use only lifting equipment adapted to the weight of the power unit
• Center of gravity is high, see label on cabinet
• Do not lift the power unit with hydraulic fluid in the tank.

Fig 4.2-1 Lifting the cabinet

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4.3 Positioning the power unit

For ease of maintenance the HPU unit has to be installed so that there is sufficient
working space around it. Remember that more working space is required for heavier
maintenance such as changing the pump/motor assembly. Additionally, this space will
secure proper ventilation of the HPU unit.
It is important to secure sufficient working space for maintenance of all plumbing for
water, air, and hydraulics.

4.4 Mounting of the cabinet feet

The cabinet feet are tapped steel plates that are welded to the deck. They are delivered
inside the HPU along with spare filter elements and accumulator charging kit.

Attach mounting feet prior to setting HPU in place, with bolts that are provided. When
HPU is located on the drawworks the mounting feet can be welded to the deck. Next lift
HPU and set aside while welder seal welds the mounting feet to the deck to prevent a
space for moisture to collect.

Fig 4.4-1 Mounting cabinet feet

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4.5 Electric connections

Safety precautions
• All electric equipment is intended to be installed and used by personnel who are
familiar with relevant safety requirements.
• Safety equipment necessary for the prevention of accidents at the mounting and
operating site must be provided in accordance with regulations of the prevailing local
authority.
• Grounding shall be carried out according to local regulations before electric
equipment is connected to the main voltage.
• All electrical supply levels must be within the limits that the equipment is constructed
for, see technical documentation and maximum rating plate.

Junction box
Connect the cables on the screw terminals inside the junction box. Make the
connections according to the electrical drawing in the attached technical documentation.

Electric motor
Major voltage connections are according to designation on rating plate.

4.6 Pipe work

When sizing hoses and hydraulic piping between the HPU, controls, and Disc Brake
Calipers, a safety factor of at least 4 times the maximum system pressure should be
used for tensile strength. Keep in mind that the equipment may be readjusted to higher
pressure in duty. Pressure losses in the pipe system should generally be kept to a
minimum. Contact a National Oilwell Varco representative for more information.

Hard plumbing
Hard plumbing should be 304 stainless steel tubing ASTM A269, A213, or equivalent.
1/2” OD tubing should have a wall thickness of .035 or more. 3/8” OD tubing should
have a wall thickness of .035 or more. 5/8” OD tubing should have a wall thickness of
.049 or more.

Pressure test
A pressure test to 1 ½ times the maximum working pressure should be performed on
the main high pressure lines to check for possible leakage.

Hoses
To avoid damage caused by vibrations it is important that the HPU be isolated by
hydraulic hoses.

The hoses must be rated for the maximum hydraulic pressure of thee system. Be sure
to allow for minimum permissible bend radius according to the data provided by the
supplier of the hoses.
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Line sizes

It is important that lines between the HPU, controls, and Disc Brake Calipers are as
short as possible.

This gives the following advantages:

1. Small compression volume in the hydraulic system. This is particularly important in
hydraulic systems with large and rapid load variations and, where quick response is
required.
2. Small power losses in the hydraulic system.
3. Lower installation costs due to smaller plumbing sizes and shorter lengths.

Tubing clamps
Tubes should be clamped with uniformly spaced clamps.
The distance between clamps should not exceed 6ft (2m) for tubes with outside
diameters between ½” (15mm) and 1 ½” (38mm).
In addition, the tubes must be clamped immediately before and after a bend. The tubes
must be clamped immediately before transition to hose as well.
The tubing clamps must be of a type permitting a certain amount of axial and radial
motion in the clamped joint and have good vibration-absorbing properties.

Storage of included components

The storage of included components must be in the same way as the power unit
(section 3.1 “Storage of the packed power unit”). Notice that the packing must not be
removed during storage.

JIC-fittings (SAE J514, ISO 8434)

Tighten fittings by hand, then tighten ¼ to ½ turn more using an appropriate wrench. Do
not over tighten the fittings.

Use correct tools, fittings can be damaged and become difficult to remove.

Be aware that all fittings may expand because of heat and vibrations. All fittings must be
checked and retighten.

Mounting of hoses
Ensure that hoses are not stressed or twisted during installation. This will prevent
premature failure. Bend radius should conform to manufacturer recommendations.

5. Commissioning
5.1 Prior to commissioning
• Read and understand this manual and other attached technical documentation.
• Visually check the whole system for signs of damage, incorrect circuitry, security of
equipment and that the degree of filtration of the filters is according to the data in the
technical documentation.
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• Check that the coupling between the electric motor and the pump is properly
mounted.
• Check that the Precharge pressure in the accumulators is in accordance with the
technical documentation.
Cleanliness
• The hydraulic system must be thoroughly cleaned on the inside.
• If you are uncertain about the cleanliness of the system it must be checked prior to
filling with oil.
Plumbing
• Are couplings properly tightened?
• Is the plumbing properly cleaned?
• Is the plumbing mounted free of stress?
• Are the lines in accordance with the installation drawing/piping plan?
Electrical System
• Check that the electric motor and control system and other electrical components
are connected to the correct voltages.
• Check the function of electrical components and monitoring system manually.
Instruments that can not be actuated can be checked for correct wiring and possibly
operated manually. Level switches and indication should be checked when filling the
tank.

5.2 Filling up the HPU with hydraulic fluid

Before filling
• Check that the correct type and quality of hydraulic fluid is used.
• Do not mix different types of hydraulic fluid.
• Check that the barrel with the hydraulic fluid and fill hoses are not contaminated with
water or other substances.
• Fill case drain on hydraulic pump by removing case drain fitting.
• Use the fill wand provided with the HPU to fill the reservoir. Never pour hydraulic
fluid from containers into reservoir.

New fluid is normally not filtered and will introduce dirt into the system; therefore,
the fluid must always be filled through a filter. Never pour hydraulic fluid into the
tank through the air breather filter.

Fill the tank to the level indicated on the tag near the sight level glass.

Check the function of the level switches during filling up of the tank.

Check caution sign on the container and the warnings (section 2.4 “choice of
hydraulic fluid”).
Avoid prolonged contact of hydraulic fluid with your skin.
Immediately clean hydraulic fluid spills from decks to prevent personal injury.

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5.3 Initial start-up procedure

Important note!
• Make sure the system is ready to run, warn all personnel on the rig floor that a start-
up is in progress.
• Follow all safety precautions including the ones in this manual.
• Never operate the power unit with defective instruments or control elements.
• During start-up period, the hydraulic system will be filtering to remove dirt particles,
therefore keep an eye on the filter indicator during the entire start-up procedure.
On cold start-up, the filters may indicate a by-pass condition. Check the indicator after a
few minutes of operation. The differential pressure across the filter will lower to normal
levels as the oil warms up. Inspect the filter elements or change them if the filter
indicators continue to show a clogged condition.

STEP 1 Immediately before starting

• Check fluid level in reservoir and refill to levels indicated on the reservoir.
• Check if any components need filling with clean hydraulic fluid, such as the pump
case.
• Check safety equipment.
• Check that all the prescribed steps (xxx “Prior to commissioning”) have been carried
out.
• Check that cooling water is connected and turned on.
For adjustments and settings on the control system see separate instruction in attached
technical documentation.

STEP 2 Start with unloaded pump.

• Starting the HPU shall be carried out with a completely unloaded pump.
• First open bleed valves on the bottom of the accumulators. This will prevent the
pump from building high pressure on start-up.
• Start pump by jogging electric motor on and off. Check rotation of motor with the
arrows on the fan shroud.
• When rotation has been confirmed, let pump run to warm up the hydraulic fluid.
• When fluid temperature approaches between 80° and 90° F begin to close bleed
valves on the bottom of accumulators.
• The system pressure should now be at specified level.

STEP 3 Bleed system of air.

• Bleed system of air with the HPU operating at the pressures detailed in the attached
technical documentation. Air needs to be bled from all Disc Brake Calipers. (SEE
BLEEDING AND FLUSHING in the Universal Disc Brake System Manual)
• Recheck the hydraulic fluid level and refill as needed after the Disc Brake System
has been bled.

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STEP 4 Checking
• Check all fittings and hoses for leaks, retighten as needed.
• Check for unusual noises or vibrations.
• Check oil temperature.
• Check all filter indicators.

STEP 5 Air back-up pump

• Turn on air to air back-up pump.
• Turn off electric motor and as pressure begins to fall the air back-up pump should
begin to run at about 100 PSI below the electric pump compensator setting. If it does
not, adjust the air pressure regulator for the air back-up pump until this pressure is
attained.
• Turn electric pump back on and air back-up pump should stall out as pressure rises
above its setting.

6.0 CORRECTIVE MAINTENANCE

6.1 TROUBLE SHOOTING

Trouble Shooting for VPV “Whisper Pumps”

Excessive 1 Coupling misalignment 1 Align the pump and motor to
Pump Noise within .006 of an inch total
indicator reading. The tighter
the alignment, the quieter the
pump will be.
2 The continuous pressure is 2 The pumps have been sound
significantly below 200 PSI tuned at rated pressure.
for 140 bar pumps Consult factory or raise
minimum pressure 300 PSI
3 Fluid in reservoir is low and 3 Fill the reservoir so that the
the pump is sucking air. fluid level is well above the
end of the suction line during
all of the working cycle
4 Restricted Inlet 4 If a suction strainer is used,
check it for obstructions or
dirt. Also, check for shop
rags left in reservoir.
5 Air leak in the suction line 5 Tighten all fittings. If it still
leaks, smear grease over the
joints to locate the leak.
6 Suction line has too many 6 The suction line should be as
elbows, or is too long. short and straight as
possible.
7 Air in fluid. 7 The return line should
terminate below the fluid
level to prevent splashing.

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8 Suction line is too small. 8 Suction line should always

be equal in size to suction
port. Never reduce it.
9 Vane does not move freely. 9 Contamination in fluid or a
burr in vane slot can cause a
vane to bind up. Proper
filtration and/or deburring of
the vane slots are required.
10 Vane is install incorrectly. 1 In vane pumps VPV, the
0 leading edge of the vanes
must be oriented in the
direction of rotation.
11 Vane is missing. 1 Make sure all vane slots
1 have a vane in them.

Trouble Shooting for VPV “Whisper Pumps”

Pump will not 12 Shaft rotation in the wrong 12 When installing a pump,
prime. direction. always jog electric motor to
check the proper rotation.
Rotation should always be
clockwise (right hand) for
VPV pumps.
13 Air leak in suction line. 13 Make sure fittings are tight.
14 Pump is air bound. 14 Use an air bleed valve to
void the pump and its suction
line of air.
15 Fluid level in reservoir is too 15 Fill the reservoir so that fluid
low. level is well above the end of
the suction line.
16 Stroke limiter is turned in too 16 Flow should not be reduced
far. more than 50% of maximum.
17 Suction port dust plug left in 17 Remove plug.
place.
Pump is 18 Contamination in the 18 Thoroughly clean the control
unstable compensator. orifices and check filtration.
19 Pressure ring is not moving 19 Control piston should be
properly. checked for freedom of
movement.
Pump is hot. 20 Case drain line is installed 20 The case drain and pump
too close to the pump inlet. inlet should be separated by
a baffle in the reservoir.
21 Reservoir is undersized. The 21 Add a cooler.
rule of thumb is a minimum of
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2 to 3 times the output flow.

6.2 Pump settings and adjustments
Bosch VPV Vane Pump

There are only two adjustments on this pump.

1. Pressure compensator
2. Volume control

Fig 6.2-1 BOSCH vane pump settings and adjustments

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6.3 VPV VANE PUMP REPAIR PARTS

Fig 6.3-1 BOSCH vane pump

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6.3 VPV VANE PUMP REPAIR PARTS

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Fig 6.3-2 BOSCH vane pump

6.4 VANE TIP ORIENTATION

Fig 6.4-1 BOSCH pump vane tip orientation

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6.5 OILGEAR TYPE “PVM” OPEN LOOP PUMPS

Nov P/N L724113-118

WARNING
Running the pump in “Neutral” position (zero delivery) for long periods of time without
supercharge can damage the pump.

Pump all fluid into reservoir through a clean (beta 10 ratio 4 or more) filter. Fill reservoir to, but
not above, “high level” mark on sight gage.
Remove case drain line and fill pump case with hydraulic fluid.
Turn driveshaft a few times by hand or with a spanner wrench to be sure parts are free.

With pump under “no load”, or with pump control at “neutral”, turn drive unit on and off several
times before allowing pump to attain full speed. Running the pump and operating the control can
usually fill the system. Watch the fluid level in the reservoir and stop pump if the level reaches
“low level” mark. Add fluid and start again. With differential (cylinder) systems, fluid must not
be above “high level” when the ram is retracted or below the “low Level” when extended. Bleed
air from the system by loosening connections or opening petcocks at the highest point in the
system. Close connections or petcocks tightly when solid stream of fluid appears.

1. MALFUNCTIONS AND CAUSES

A. UNRESPONSIVE OR SLUGGISH CONTROL
1. Swash block saddle bearing worn or damaged.
2. Control piston or sequence spool binding in bore.
3. Control piston spring broken, sequence valve spool spring binding or otherwise damaged.

B. INSUFFICIENT PUMP VOLUME

1. Delivery limited by stroke limiter screw,
2. Delivery limited by faulty control piston, or control relief valve operation.
3. Obstructed suction circuit or insufficient supercharge volume.
4. Insufficient drive motor speed.
5. Worn or grooved cylinder barrels, port plate and/or valve plate matching surfaces.
6. Worn or broken saddle bearing.
7. Worn or damaged piston and shoe assemblies or piston bores in cylinder.
8. Worn or damaged piston shoe or swash block.

C. IRREGULAR OR UNSTEADY OPERATION

1. Faulty control piston, sequence valve or control valve operation.
2. Fluid level in reservoir is low or supercharge is insufficient.
3. Air entering hydraulic system.

4. Worn axial piston pump.

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5. Faulty output circuit components (cylinders, motors, valves etc.).

D. LOSS OF PRESSURE
1. Worn piston pump.
2. Worn or grooved cylinder barrel, port plate and/or valve plate matching surfaces.
3. Worn piston and shoe assemblies or piston bores in cylinder.
4. Faulty output circuit components.
5. Worn or broken saddle bearing.

E. EXCESSIVE or HIGH PEAK PRESSURE

1. Faulty control piston, sequence valve or control valve operation.
2 Faulty output circuit components (pay particular attention to system relief valves).
3. Worn or broken saddle bearing.

F. EXCESSIVE NOISE
1. Pump incorrectly being stopped or started under load.
2. Low fluid level in reservoir or insufficient supercharge resulting in cavitation.
3. Air entering hydraulic system.
4. Fluid too cold or viscosity too low.
5. Suction line problem i.e.; obstructions in line, line too long, line diameter too small or too
many bends and/or loops in line.
6. Broken or worn piston and shoe assemblies.
7. Pump rotating in wrong direction.

G. EXCESSIVE HEATING
1. Operating pump above rated or peak pressure.
2. Low fluid level in reservoir or insufficient supercharges.
3. Air entering hydraulic system.
4. Worn piston pump.
5. Worn or grooved cylinder barrel, port plate and/or valve plate.
6. Faulty output circuit components (continuous blowing relief valves or “slip” through valves,
cylinder, etc.).
7. Insufficient cooling provision or clogged coolers.

2. TESTING AND ADJUSTING

WARNING – Shut pump off and release pressure from system before disassembling
components. Failure to comply with these instructions could result in personal injury or
death. Blocking pressure line between pump and system (or pump) high pressure relief
valve will result in damage and could result in personal injury.

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Fig 6.5-1 Oilgear PVM piston pump assembly

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6.6 AIR BACK-UP PUMP SERVICE AND OVERHAUL INSTRUCTIONS

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6.6 AIR BACK-UP PUMP SERVICE AND OVERHAUL INSTRUCTIONS

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6.6 AIR BACK-UP PUMP SERVICE AND OVERHAUL INSTRUCTIONS

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6.6 AIR BACK-UP PUMP SERVICE AND OVERHAUL INSTRUCTIONS

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6.6 AIR BACK-UP PUMP SERVICE AND OVERHAUL INSTRUCTIONS

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6.6 AIR BACK-UP PUMP SERVICE AND OVERHAUL INSTRUCTIONS

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6.7 HPU DETAIL

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Fig 6.7-1 HPU detail

6.7 HPU DETAIL

Fig 6.7-2 HPU detail

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6.7 HPU DETAIL

Fig 6.7-3 HPU detail

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6.8 RECOMMENDED SPARES and SERVICE PARTS

RECOMMENDED SPARES and SERVICE PARTS
ITEM NO. DESCRIPTION NATIONAL PART NO.
1 TANK BREATHER FILTER 7805734
1A*(2) REPLACEMENT ELEMENT 7804882
2 SUCTION FILTER 7805833
2A*(2) REPLACEMENT ELEMENT 7804881
3 HIGH PRESSURE FILTER 7805831
3A*(2) REPLACEMENT ELEMENT 7804879
4 RETURN FILTER 7805832
4A*(4) REPLACEMENT ELEMENT 7804880
5 FILTER-REGULATOR 7805835
5A*(2) REPLACEMENT ELEMENT 7804370
5B*(2) REPAIR KIT 7810667
5C*(2) AUTO-DRAIN ELEMENT 7810668
6*(1) SYSTEM RELIEF VALVE CARTRIDGE 7500683
7*(1) PRESSURE REDUCING VALVE 7500693
8 FILL PUMP 7815438
9 MAIN PUMP 7815437
9A*(2) REPAIR KIT 7810663
9B*(2) SEAL KIT 7810664
10 AIR BACK-UP PUMP 7815201
10A*(2) OVERHAUL KIT 7810619
11 HYDRAULIC ACCUMULATOR 7800771
11A*(2) REPAIR KIT 7810666
11B* (2) AIR VALVE REPAIR KIT 7810638
12*(2) PRESSURE GAUGE 0-200 PSI 7806846
13*(2) PRESSURE GAUGE 0-2000 PSI 7806851
14*(2) PRESSURE GAUGE 0-3000 PSI 7806852
15*(1) NEEDLE VALVE 7500665
16*(1) WATER MODULATING VALVE 7500680
17*(1) EMERGENCY RELEASE/SET VALVE 7500694
18*(1) SHAFT COUPLING 7828306
* DENOTES RECOMMENDED SPARES

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6.9 RECOMMENDED SERVICE INTERVALS

RECOMMENDED SERVICE INTERVALS

CHANGING AFTER THE FIRST 40 HRS OF OPERATION
HYDRAULIC FILTER THEN EVERY 500 HRS. THEREAFTER
ELEMENTS
CHANGING AIR FILTER AFTER THE FIRST 40 HRS OF OPERATION
THEN EVERY 250 HRS THEREAFTER
LUBRICATE AIR BACK- ONCE A MONTH REMOVE AND GREASE VALVE SPOOL
UP PUMP MAIN AIR
VALVE
BREATHER FILTER CHANGE EVERY SIX MONTHS
HYDRAULIC FLUID CHANGE FLUID ONCE EVERY YEAR, CLEAN OUT
RESERVOIR WHEN CHANGING FLUID

7. TECHNICAL DOCUMENTATION
7.1 Power requirements
Power requirements for the UDBHPU as follows:
460 VAC 60 Hertz 3 phase @ 15 amperes.

7.2 Cooling Water

Cooling water requirement: 5 to10 gallons per minute of fresh water @ 60 to 90°F

7.3 Air Supply

Air supply requirements: 75 to 80 CFM @ 100 PSI

7.4 Pressure settings for operating National 1625 UDB Drawworks

The following pressure settings are for National Oilwell Varco 1625 UDB Drawworks:

1. Main Pump Compensator: 2,000 PSI

2. Service Caliper Pressure: 1,200 PSI
3. Air Back-up Pump Output: 1,900 PSI
4. System Relief Valve Setting: 2,350 PSI
5. Accumulator Pre-charge: 1,200 PSI

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7.5 Hydraulic Schematic

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7.6 Electrical Schematic

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8 Design phases

8.1 Phase I covers:

1. 2111731
2. 2111818
3. 2111836
4. 2111951
5. 2111960
6. 2112045
7. 2112166
8. 2112287
9. 2112292

Major components include:

BOSCH vane pump
Tube and shell oil cooler
Fairey Arlon oil filter
MOOG valves 62K series

For a typical Phase I assembly see Fig 8.1-1,2,3 from EPL 1690

8.2 Phase II covers:

1. 2112302
2. 2112356

Major components include:

Oilgear piston pump
Plate type oil cooler
Fairey Arlon oil filter
MOOG valves series D633 with remote amplifiers

For a typical Phase II assembly see Fig 8.2-1,2,3,4. from EPL 1692

8.3 Phase III covers:

1. D811000629-DOS-001
2. D811000630-DOS-001
3. D811000633-DOS-001

Major components include:

Oilgear pump Hi Temp
Larger size plate type oil cooler
Hydac oil filter with integrated breather
MOOG valves series D635 with integrated amplifiers
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For a typical Phase III assembly see Fig 8.3-1,2. from D811000629-DOS-001.

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Fig 8.1-1
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Fig 8.1-2
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Fig 8.1-3
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Fig 8.2-1
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Fig 8.2-2
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Fig 8.2-3
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Fig 8.2- 4
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Fig 8.3-1
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Fig 8.3-2
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