NB/SH/T 0830-2010 Determination of wear characteristics of non-petroleum-based and petroleum-based hydraulic fluids by vane pump method

AI-translated method card — human verification pending. This is not an official translation of the standard. Unclear source values remain unverified; check the original standard and product certificate before use.

Incomplete source card: Sections 9, 10, 11, 12, 13, 14 are absent from the available source. Only available content is translated; source completion is pending.

Card type: Test method

1. Method number / full name / English name / replacement relationship

• Standard number: NB/SH/T 0830-2010
• Chinese name: Determination of wear characteristics of non-petroleum-based and petroleum-based hydraulic fluids by vane pump method
• English name (original): Standard test method for indicating wear characteristics of non - petroleum and petroleum hydraulic fuids in a constant rolume vane pump (original as such, fuids / rolume suspected to be source-text extraction noise, requires confirmation against the source standard (source-text extraction))
• Replacement relationship: not provided in the available source (no replacement of any standard mentioned)
• Adoption relationship: modified adoption of ASTM D7043-04a "Determination of wear characteristics of non-petroleum-based and petroleum-based hydraulic fluids by vane pump method", and redrafted according to ASTM D7043-04a
• Main technical differences from ASTM D7043-04a (original foreword):
  • The referenced standards adopt and supplement the corresponding national standards and industry standards of our country
  • Added three informative annexes: Annex A, Annex B, and Annex C
  • Editorial modifications: some supplements were made to the test equipment, instruments, and reagents and materials; the original "Chapter 10 Flushing", "Chapter 11 Preparation of the test pump cartridge", "Article 1 and Article 2 of Chapter 12" were modified and supplemented according to the practice of our country, and merged into "Chapter 10 Test preparation"
• Publication / implementation: published on 2010-05-01, implemented on 2010-10-01
• Issuing authority: National Energy Administration
• Drafting organization: Dalian Lubricant Research and Development Center of PetroChina Company Limited
• Main drafter: Liang Dejun
• Custodian: Subcommittee on Petroleum Fuels and Lubricants of the National Technical Committee for Standardization of Petroleum Products and Lubricants
• Proposed by: China Petrochemical Corporation

2. Scope of application and non-applicability

• 1.1 This standard specifies the operating procedure for the vane pump test at 1200r/min and 13.8MPa.
• 1.2 This standard uses the International System of Units [SI] units.
• 1.3 The application of this standard may involve certain hazardous materials, operations, and equipment, but it does not purport to address all safety issues associated with them. Users are responsible for establishing appropriate safety and protection measures before using this standard, and for determining the applicability of relevant regulatory limitations.
• Non-applicable scope: no explicitly listed non-applicable clauses are provided in the available source.

3. Method principle

• Chapter 4 Method summary: under the conditions of a pump speed of 1200r/min ±60r/min and a pump outlet pressure of 13.8MPa ±0.3MPa, 18.9L ±0.5L of test fluid is circulated through the vane pump bench for 100h.
• Temperature conditions:
  • For water-containing glycol, emulsions, other water-containing liquids, and petroleum-based oils and synthetic oils with a viscosity at 40℃ equal to or lower than 50.6mm²/s, the pump inlet temperature is 66℃±3℃;
  • For all other petroleum-based oils and synthetic oils, the pump inlet temperature is 80℃±3℃.
• The total pump wear (mass loss of the stator and twelve vanes during the test), the condition of the pump parts after the test, and the initial and final flow rates of the pump are used as test results to evaluate the anti-wear characteristics of the test fluid.
• Chapter 5 Significance and use: mainly used to determine the wear characteristics of non-petroleum-based and petroleum-based hydraulic fluids in a vane pump. Excessive wear of the vane pump may cause failure of the hydraulic system under severe service conditions.

4. Reagents and materials (purity / preparation)

• 7.1 Solvent naphtha: meets the requirements of No. 2 and No. 5 solvent naphtha in GB 1922, or an equivalent product.
• 7.2 Petroleum ether: analytical reagent, meets the requirements of GB/T 15894, or an equivalent product.
• 7.3 Isopropanol: analytical reagent, meets the requirements of GB/T 7814, or an equivalent product.
• 7.4 Sandpaper: P1200 water-resistant sandpaper, meets the requirements of JB/T 7499.
• Warning: the use of all solvents shall comply with safety regulations.
• Other prepared solutions (original 10.1.3.5): a mixed solution of No. 2 solvent naphtha of 50% and isopropanol of 50% (used for soaking metal parts after water cleaning).
• Amount of test fluid: prepare about 26.5L of test fluid (original 9.1); during the test, add about 12L of test fluid to the oil tank (original 11.1.2); during flushing, add 7.6L of cleaning fluid or test oil (original 10.1.2.4, 10.1.2.11).

5. Instruments and equipment

• 6.1 The basic system includes the following equipment (see Figure 1):
  • 6.1.1 AC motor, or other suitable driving equipment: speed 1200r/min, power at least 11kW.
  • 6.1.2 Test bench base, matching components of the motor, pump, oil tank, and other components.
• Figure 1 System schematic components (listed in the original): oil tank; pump inlet temperature sensor; pump; flexible coupling; motor; pump outlet pressure gauge; mechanical gauge snubber valve (requires confirmation against the source standard (source-text extraction)); pressure regulating valve; filter; heat exchanger; temperature electric regulating valve; turbine flowmeter; pressure gauge; sampling port; oil inlet line valve*; oil return line valve*; pump inlet pressure gauge*; pump outlet temperature sensor*; drain valve; oil tank temperature sensor*; liquid level control relay* (* mark indicates that this accessory is not required).
• Required dimensions: A. vertical distance 61cm~66cm; B. horizontal distance not less than 15.2cm; C. 10.2cm.
• 6.1 Replaceable pump cartridge type rotary vane pump: Vickers 104C or Vickers 105C, at a speed of 1200r/min, ISO viscosity grade 32, temperature 49℃, pressure 6.9MPa, the flow rate of the test fluid is 28.4L/min (see Figure 2 and Figure 3). Warning: protective guards shall be provided for the exposed rotating parts of the pump.
  • Note: the standard is abbreviated for the pump cartridge of the American Conestoga company, and the pump body and pump cover of Vickers (the original "Coneslog" is suspected to be source-text extraction noise, requires confirmation against the source standard (source-text extraction)). If accessories manufactured by other companies are used, please refer to test method ASTM D2882-00 for test preparation and selection guidance.
• 6.1.3 The pump cartridge to be replaced includes: stator, rotor, two port plates, a set of thirteen vanes, and one positioning pin.
• 6.1.3.2 Individual pump cartridge components can be purchased separately. The product models of components from the American Conestoga company are: stator 2882-5, positioning pin 2882-10, rotor 2882-1C, port plates 2882-4C and 2882-4B, vanes (1 vanes) 7882-V12.
• 6.1.3.3 No modification to the pump body is required, such as plugging the drain hole in the pump body or drilling an external drain port in the pump cover.
• 6.1.4 Oil tank:
  • 6.1.4.1 The oil tank shall have a movable baffle and a matching cover, all made of stainless steel. The oil tank may be cubic or rectangular (with a spherical or conical bottom), and its design must ensure that air is prevented from entering with the test fluid.
  • 6.1.4.2 In order to promote sufficient degassing of the test fluid and heat exchange, the residence time of the test fluid in the oil tank should be maximized, so the test fluid flowing in from the return port to the outlet should flow in a circuitous route according to the path designed by the baffles.
  • 6.1.4.3 To avoid entraining air, the inlet of the oil return line of the oil tank should be designed below the liquid level of the test fluid, avoiding the test fluid from spraying above the baffles, and shall be at least 15cm in height from the centerline of the pump inlet.
  • 6.1.4.4 Additional openings may be equipped with a low liquid level control switch, oil tank temperature sensor, low-position drain port, etc., as required by the user.
  • 6.1.4.5 If the oil tank is fixed in position, a liquid level observation port may be added on the side of the oil tank so that the degassing condition inside the oil tank can be observed without opening the cover.
• 6.1.5 Outlet pressure regulation: Vickers pressure regulating valve (CT-06-G/3.45MPa~43.8MPa) with manual control or automatic control (see Figure 4).
• 6.1.6 Temperature control device: controls the flow rate of cooling water in the heat exchanger to maintain the test fluid within the specified temperature range.
• 6.1.7 Temperature display: the accuracy should reach (original numerical value missing, requires confirmation against the source standard (source-text extraction)), and a suitable sensor shall be provided to detect the pump inlet temperature.
  • 6.1.7.1 To avoid obstruction of liquid flow near the pump inlet, the diameter of the thermocouple insertion port shall not exceed 6mm.
  • 6.1.7.2 The temperature of the test fluid should be measured within 10.2cm from the pump inlet. The contact of the thermocouple shall be inserted into the center of the liquid flow.
  • Note: the user may add a pump outlet temperature sensor as an effective monitoring tool. However, it is required to meet the 13.8MPa working pressure and be installed on the high-pressure line between the pump and the regulating valve (18 in Figure 1).
• 6.1.8 Heat exchanger: shall have sufficient heat exchange area to remove excess heat from the test system. Note: a shell-and-tube heat exchanger is recommended; if used, it should be connected at the back (the hydraulic fluid flows through the tubes without surrounding them) to ensure effective cleaning of the heat exchanger between tests.
• 6.1.9 Pressure display: the pump outlet pressure at 13.8MPa should reach an accuracy of at least 0.3MPa.
  • 6.1.9.1 The pressure display shall be provided with a buffer tube to prevent damage to the pressure display due to oscillation or fluctuation of the system pressure.
• 6.1.10 Filter device: has a housing, the filter element is made of glass fiber and is replaceable, and its performance should reach β≥100 (the filtration ratio of a filter with a filtration accuracy of 3μm at β-). Two new filter elements are required for each test.
  • 6.1.10.1 The filter housing does not need a bypass; a pressure gauge should be installed at both ends, or a differential pressure sensor should be used to monitor the pressure at both ends of the filter to prevent failure.
  • 6.1.10.2 If dual pressure gauges are used to detect the filter pressure, the pressure difference between the two pressure gauges can determine whether the filter unit is normal. The pressure at which a failure occurs should be within the rated range of the gauges.
• 6.1.11 Flow measurement device: accuracy at least 0.4L/min.
• 6.1.12 Even if not required, it is recommended to install low liquid level, high pressure, high temperature, and low flow safety self-protection systems.
• 6.1.13 It should be checked to ensure that the flushing fluid and test fluid are compatible with hoses, seals, or any other materials in the system. Note: materials such as electroplated iron, aluminum, zinc, and cadmium should be avoided in hydraulic systems because they are highly corrosive in non-petroleum-based hydraulic fluids.
• 6.1.14 Flexible motor coupling.
• 6.2 The various components of the test system are assembled as shown in Figure 1:
  • 6.2.1 The test system should be equipped with the necessary drain valves to ensure that the system oil is completely drained with no residue.
  • 6.2.2 When establishing the test system, high-quality hydraulic lines should be selected to prevent air from entering and affecting the test.
  • 6.2.3 The installation of the test pump should ensure that it is easy to inspect and clean the inner surface of the pump body, easy to check coaxiality, and easy for the operator to disassemble and assemble the test pump cover.
  • 6.2.4 The oil tank position should be higher than the test pump. After the test system is filled with test fluid, the liquid level in the oil tank should be able to be between 61cm and 66cm above the centerline of the pump. When the oil tank is above the centerline of the pump, the test system will be filled with test fluid.
    • 6.2.4.1 The oil tank should be positioned so that it is easy to drain and fill the test fluid, and easy to observe the liquid level by opening the cover or through a monitoring port.
  • 6.2.5 Oil inlet line (from oil tank to test pump inlet): minimum inner diameter is 25mm, and the straight pipe length before the test fluid enters the test pump inlet is at least 15cm (the extracted wording is suspected to mean "minimum", requires confirmation against the source standard (source-text extraction)). If a hose is used, there must be sufficient excess.
    • Note 1: The user may install a compound pressure gauge near the pump inlet as an effective monitoring tool (see 17 in Figure 1). However, it should be ensured that any opening added at the pump inlet cannot become an air infiltration point.
    • Note 2: When installing the pump oil inlet line, some users are accustomed to using a semicircular pipe instead of a bent pipe. Then the straight pipe length specified in 6.2.5 should be measured between the end of the semicircular pipe and the pump inlet. It is recommended to use a semicircular pipe with an inner diameter of 25mm and a bending radius of 100mm.
  • 6.2.6 High-pressure line (from pump outlet to pressure regulating valve): minimum rated pressure is 14MPa, minimum inner diameter is 15mm.
  • 6.2.7 Return line and equipment (from pressure regulating valve to filter, flow meter, heat exchanger, oil tank): minimum rated pressure is 3MPa, minimum inner diameter is 15mm.
    • Note: Some users have found that adding a shut-off valve to the pump return line (see 16 in Figure 1) is a useful accessory for the line, as it allows replacement of filters and other system maintenance without draining the oil tank.
    • Warning: If a valve is installed on the pump return line, the user should follow procedural steps before system startup to determine that this valve is open; if it is not open, low-pressure system components will rupture.
    • Note: Some users have found that adding a shut-off valve to the pump oil inlet line (see 15 in Figure 1) is a useful accessory for the line, as it allows replacement of filters and other system maintenance without draining the oil tank. It is recommended to use a full-flow valve with an opening of at least 25mm.
    • Warning: If a valve is installed on the pump oil inlet line, the user should follow procedural steps before system startup to determine that this valve is open; if it is not open, the pump will be evacuated.
• 6.3 System auxiliary equipment and instruments:
  • 6.3.1 Demagnetizer.
  • 6.3.2 Cooling water system.
  • 6.3.3 Instrument circuit control system.
  • 6.3.4 Oil cleanliness tester.
  • 6.3.5 Platform.
  • 6.3.6 Balance: range is 0g~200g, sensitivity is 0.001g.
  • 6.3.7 Box-end wrench, open-end wrench, torque wrench, etc.

6. Recommended operating conditions

• Pump speed: 1200r/min ±60r/min
• Pump outlet pressure: 13.8MPa ±0.3MPa
• Pump flow rate: >15.0L/min
• Temperature:
  • Water-containing glycol, emulsions and other water-based fluids: 66℃±3℃
  • 40℃ Petroleum-based oils and synthetic oils with viscosity equal to or lower than 50.6mm²/s: 66℃±3℃
  • All other petroleum-based oils and synthetic oils: 80℃±3℃
• Test time: 100h (uninterrupted operation)
• Test fluid volume: 18.9L ±0.5L (method summary); during the test, add approximately 12L (11.1.2) to the oil tank
• Break-in phase (11.3): adjust pump outlet pressure to 2.1MPa; within 1h, carry out temperature rise through 6 10min steps, while increasing pump outlet pressure, with pressure levels respectively 2.1MPa, 4.1MPa, 6.2MPa, 6.9MPa, 10.3MPa (the original text "10 SMPao" is suspected to be source-text extraction noise, requires confirmation against the source standard (source-text extraction)) and 12.4MPa.
• Flushing conditions (10.1.2.7, 10.1.2.14): flush the system under conditions of 1200r/min ±60r/min speed, 0.7MPa pressure and 38℃~49℃ for 30min.

7. Sampling and specimen preparation

• 9.1 Prepare approximately 26.5L of test fluid.
• 9.2 The test fluid should be able to represent the properties of the oil being tested, and each portion extracted for testing should also be able to represent the test fluid.
• The sampling port is shown in Figure 1 (number 14).
• Other content of specimen preparation: not provided in the available source.

8. Analysis procedure

• Chapter 8 Test bench maintenance:
  • 8.1 Temperature, pressure sensors and control switches should be checked regularly to maintain their normal operation.
  • 8.2 The pump shaft, shaft seal and bearings are preferably replaced every 5 tests (if there is large mass loss, operational vibration, cavitation or visible damage, they should be replaced promptly) (see Figure 2).
    • 8.2.1 The pump requires various sealing materials. The most suitable sealing material should be used for any given test fluid.
  • 8.3 Inspect the pump body and pump cover:
    • 8.3.1 Inspect the pump cover and pump body inner cavity; if obvious damage is found, replace promptly.
    • 8.3.2 After the pump is disassembled for replacing oil seals and bearings, carefully inspect the pump body and pump cover, check the contact surfaces of the pump cover and pump body with the port plate (see Figure 5, surfaces A and B) for spots, misalignment, or other damage. Replace problematic parts.
    • 8.3.3 Inspect the pump cover bearing; it should be an interference fit into the pump cover. If it is loose, replace the pump cover.
    • 8.3.4 Inspect the tightness of the fit between the main shaft bearing and the pump body; if it is loose, replace the pump body.
    • 8.3.5 Inspect the inner diameter of the pump body (see Figure 5, diameter E), the maximum should not exceed 76.23mm. If the bore diameter is too large, the stator may be damaged when the pump is pressurized. If the bore diameter is too large, a thin shim cut to length 235mm, width 20mm, thickness 0.025mm can be evenly wrapped around the stator to fill the remaining gap. The shim needs to be installed after the pump cartridge has been installed, and the pump body bore and the outside of the stator must be clean and dry.
    • 8.3.6 Check whether the pump body inlet and outlet correspond to the port plate inlet and outlet; they must not be misaligned, otherwise it will obstruct the flow of test fluid.
    • Note: When continuous operational problems occur and no obvious cause can be found, the pump body, pump cover, or both should be replaced, which can alleviate these problems.
  • 8.4 Inspect the main shaft (see Figure 6):
    • 8.4.1 Check whether the splines of the new shaft are smooth, whether the width from the outer diameter to the root is consistent, and whether they are parallel to the axis. If the rotor has worn deep marks on the shaft, the main shaft needs to be replaced (see 1, 2, 3, 4 in Figure 6).
    • 8.4.2 How the shaft differs from those that have failed due to use or are bent, twisted, or have damaged keyways or key teeth due to overheating (see 5 in Figure 6).
    • 8.4.3 Check whether the shaft seal is intact to avoid shaft seal leakage (see 6 in Figure 6).
  • 8.5 Check the coaxiality of the pump and motor shafts: non-parallelism should not be greater than 0.08mm, angular error should not be greater than 0.7 (the original numerical unit is missing, requires confirmation against the source standard (source-text extraction)).
    • 8.5.1 Coaxiality should be completed under the condition that the pump cartridge is installed.
    • 8.5.2 Use a dial indicator, remove the motor coupling, rotate the shaft by hand, and check the shaft for bending (see 7 in Figure 6).
    • 8.5.3 Precision measurement with the same outer diameter: rotate the shaft connected to it, use a straightedge and feeler gauge to measure the coaxial precision of the shaft (pump or motor).
  • 8.6 Regularly inspect the eight screw holes on the pump cover: apply anti-rust oil to the threads to prevent corrosion; in order to better secure the test pump cartridge, any damaged threads of the pump body and pump cover screws should be replaced promptly.
  • 8.7 The pressure regulating valve needs to be disassembled regularly: clean and inspect (the garbled wording about cleaning and inspection is suspected to be source-text extraction noise, requires confirmation against the source standard (source-text extraction)).
• Chapter 10 Test preparation:
  • 10.1 Flushing: used respectively for tests of petroleum-based hydraulic oil and synthetic oil, water glycol and other water-based fluids.
    • 10.1.2 Flushing procedure for petroleum-based hydraulic oil and synthetic oil (original text 10.1.2 each item):
      • Drain the old oil from the system. Remove the used test pump cartridge and old filter element. Empty the pump, filter housing, oil tank and partition.
      • Flush the pump cartridge (any good, previously used pump) and new filter element.
      • Close all drain valves and tighten the pump cover torque screws, open the pump oil inlet line valve and return line valve.
      • Add 7.6L cleaning fluid. In this method, it is recommended to use No. 5 solvent oil. Note: When one type of oil has been tested, flushing once with this petroleum-based solvent is usually sufficient. Other solvents are only used when oxidized oil adheres to the oil tank and oil lines.
      • If the cleaning fluid after the first flush is turbid or opaque, the flushing should be repeated.
      • Fully open the pressure regulating valve to ensure that no pressure is generated at the start of flushing.
      • Repeatedly lightly press the pump motor "on" and "off" buttons to expel air from the test system until the cleaning fluid returning to the oil tank can be seen to be free of air.
      • Flush the system under conditions of 1200r/min ±60r/min speed, 0.7MPa pressure and 38℃~49℃ for 30min.
      • Drain the cleaning fluid from the system and flush the pump cartridge. Empty the pump, filter housing, oil tank and partition.
      • Reinstall the used pump cartridge.
      • Close all drain valves and tighten the pump cover torque screws, open the pump oil inlet line valve and return line valve.
      • Add 7.6L test oil to the system.
      • Fully open the pressure regulating valve to ensure that no pressure is generated at the start of flushing.
      • Repeatedly lightly press the pump motor "on" and "off" buttons to expel air from the test system until the test oil returning to the oil tank can be seen to be free of air.
      • Flush the system under conditions of 1200r/min ±60r/min speed, 0.7MPa pressure and 38℃~49℃ for 30min.
      • Drain all oil from the system.
      • Remove the flushing pump cartridge.
      • Remove the used filter element and install a new filter element.
    • 10.1.3 Flushing procedure for water-glycol and other water-based fluids:
      • 10.1.3.1 In order to clean the water-glycol test system, the system needs to be disassembled, including the pump body, heat exchanger, pressure regulating valve, etc.
      • 10.1.3.2 Repeatedly scrub the rubber hose with water and a brush. Then rinse with water again, and then blow dry with compressed air. Check whether the hose is cracked, hardened, or sticky. Replace if necessary.
      • 10.1.3.3 Rinse with water, then blow dry with compressed air the other rubber parts and gaskets, and check for wear, cracks, and stickiness. Replace if necessary.
      • 10.1.3.4 Clean the metal parts with water, then scrub vigorously with a soft-bristle brush, then rinse again with water, and finally blow dry with air. Use a 6.4mm diameter brass brush or other suitable brush to scrub the heat exchanger tubing. Use a tube brush to scrub the metal tubes and holes in the casting.
      • 10.1.3.5 After water cleaning is completed, place all metal parts in a mixed solution of 50% of 2 solvent naphtha and 50% of isopropanol and soak with agitation for at least 30min. Then remove the parts and blow dry with compressed air.
      • Note 1: When operating water-glycol and other water-based fluids versus operating other fluids, such as polyol esters and mineral oils, the cleaning fluids used in the system should not be the same; special attention should be paid to this point.
      • Note 2: Hoses that have already been used in mineral oil, phosphate ester, polyol ester, or poly α- olefin fluids cannot be used again in water-glycol testing.
  • 10.2 Preparation of the test pump cartridge:
    • 10.2.1 Figure 2 and Figure 3 show all the component parts of the pump cartridge.
    • 10.2.2 Inspect all component parts of the pump cartridge for machining or material defects. Use a new stator and a new set of vanes for each test. If the rotor and port plate can ensure normal testing, they may be reused.
    • 10.2.3 The operator must be familiar with precision inspection and be able to skillfully use high-quality tools.
    • 10.2.4 Rotor selection and preparation:
      • 10.2.4.1 Between two tests, it must be ensured that there is no adhering matter or other burrs on the rotor surface, journals, and slot areas; these factors will hinder the free movement of the vanes.
      • 10.2.4.2 If necessary, polish both faces of the rotor on a surface plate or other suitable flat surface with abrasive paper (see Figure 8). The rotor journals may be protected by placing them at the vertical edge of the surface plate or by wrapping protective strips around the journals, and pushing the rotor along the direction of the abrasive paper so that the rotor rotates 1¼ (original text as such, requires confirmation against the source standard (source-text extraction)).
      • 10.2.4.3 Sometimes a steel strip or copper strip wrapped with abrasive paper must be used to polish the inner surfaces of the rotor slots to remove surface corrosion and burrs.
      • 10.2.4.4 If necessary, the rotor journals may be polished bright with abrasive paper.
      • 10.2.4.5 Brush-clean the rotor and slots with 2 solvent naphtha, remove all grit and oil contamination, and dry in air.
      • 10.2.4.6 Confirm that clean vanes can move freely in the rotor slots.
      • 10.2.4.7 Inspect used rotors for obvious wear marks on the guiding surfaces of the rotor slots when the vanes are fully thrown out (see Figure 9), and for excessive use of the vanes inserted in the slots. Replace these defective rotors.
      • 10.2.4.8 Measure and record the thickness of the twelve segments of the rotor. When the dimensional variation of these segments exceeds 0.005mm, replace the rotor.
    • 10.2.5 Roll the pin on a surface plate to determine whether it is straight. Replace bent pins. Note: The size of the clearance between the stator and rotor and between the rotor and vanes, the concavity and thickness of the port plate, and the torque of the pump cover screws are judged by the operator. The values given in this chapter may serve as initial guidance, and generally low-viscosity fluids require smaller clearances and a well-matched port plate; the operator should judge based on experience.
    • 10.2.6 Select a set of components, and the average thickness of the rotor is smaller than the stator thickness by 0.017mm–0.035mm. Select a set of vanes whose dimensions are smaller than the average rotor thickness by 0.002mm–0.015mm. Some stator and vane dimensions are already marked on the packaging at the factory.
    • 10.2.7 Select a pair of port plates with similar thickness and concavity. Calculate the measured concavity values of the port plates; some are already marked on the packaging. There should be an increase of 0.0025mm from the outer diameter end of the port plate to the journal area; a relatively larger number indicates greater concavity.
    • 10.2.8 Clean the pump cartridge components with 2 solvent naphtha, then rinse with petroleum ether, and air dry.
    • 10.2.9 Demagnetize the stator and vanes with a demagnetizer. Weigh the mass of the stator and a set of twelve vanes separately. The two mass values weighed should be accurate to 0.001g and recorded. Note: Magnetism will affect the performance of the electronic balance.
  • 10.3 Assembly of the test pump cartridge (see Figure 3 and Figure 9):
    • Note: Assembly is best done by assembling directly into the pump body; this is more suitable than on a workbench. Because when a preassembled pump cartridge group is installed into the pump body, the parts are often misaligned.
    • 10.3.1 Carefully apply a thin film of test fluid to all clean surfaces of the pump cartridge components.
    • 10.3.2 Ensure that the interior of the pump body and the pump cover are clean. Note: Impurities on the sealing surfaces between the port plate and the pump body and between the port plate and the pump cover (see Figure 5, surfaces A and B) will cause reduced pump flow and internal leakage.
    • 10.3.3 Install the port plate (2882-4C) into the pump body, press it tightly against the pump body and ensure it can rotate, confirming a suitable fit. Align the locating pin holes of the port plate with the pin holes of the pump body.
    • 10.3.4 Insert the stator (2882-5) so that the side with the larger locating pin hole diameter faces the operator. Ensure that the stator is pressed tightly against the port plate, and align the stator locating holes with the locating pin holes of the port plate and the pump body.
      • 10.3.4.1 If the additional stator shim described in 8.3.5.2 is used, after installation, if the stator can move within the pump body, remove the stator and shim and reinstall.
    • 10.3.5 Align and insert the locating pin (2882-10) to the bottom. The thick end of the pin should point toward the operator, and the thick end of the pin should protrude about 8mm above the stator surface.
    • 10.3.6 Insert the rotor (2882-1C), and confirm the direction of rotor rotation is counterclockwise.
    • 10.3.7 Insert the vanes (7882-V12) into the rotor slots. Ensure that when the rotor rotates counterclockwise, the chamfered edges of the vanes are opposite to the direction of the contact surface with the stator.
      • 10.3.7.1 During assembly, ensure that the vanes can move freely in the rotor slots. If the vanes cannot move freely, remove the rotor and check the rotor slots and vanes for dirt and burrs.
    • 10.3.8 Insert the outer port plate (2882-4B) and align the pins. The thick end of the pin should protrude about 3mm above the port plate surface.
  • 10.4 Pump torque:
    • Install the seal ring, pump cover, and pump cover screws, and tighten the pump cover screws by hand.
    • Close all drain valves, and open the pump inlet line valve and return line valve.
    • Fill enough test fluid from the oil tank to ensure that the test fluid can fill the pump body.
    • Tighten the eight pump cover screws with a torque wrench (see Figure 7). The maximum torque increment each time is 1.13N·m, performed alternately in the following order: top right (1), bottom left (2), bottom right (3), top left (4), then screws (5), (6), (7), and (8). At the end of each tightening cycle, slowly rotate the pump shaft by hand. Record the final torque reading (usually about 4.52 N·m~7.91N·m). The pump should rotate by lightly turning the shaft and should not have any resistance.
    • 10.4.2 The phenomenon of sticking is when the shaft is stuck and obstructed at a certain point during smooth rotation, or is completely seized and stopped, requiring a relatively large external force to make the shaft rotate, or both phenomena exist simultaneously.
    • 10.4.4 If sticking occurs when the torque is less than 3.39 N·m, there may be misalignment in the pump cartridge group. It should be disassembled and all components inspected.
    • The coupling between the pump and the motor may be disconnected to eliminate part of the resistance caused by the motor torque when rotating the pump shaft.
    • The reverse tightening process (i.e., 2-1-4-3-8-7) will help avoid sticking or crushing the pump cover.
    • To obtain more torque, brass shims may be used under the pump cover screws to reduce friction.
    • Ensure that the pump cartridge seat faces the sealing surfaces of the pump body and pump cover (see Figure 5, planes A and B); test strips may be used between the pump cover and pump body when tightening the pump cover screws. This technical requirement requires that the pump cover, pump body, and bottom (see Figure 5, planes A and C, B and D) have parallel planes and precise measurements (see Figure 5, measurements W and X), and when the pump cartridge is fully aligned, the clearance (Z) equals T (pump cartridge thickness) + W. During the tightening procedure, the clearance around the pump cover and the pump body should be the same to prevent crushing the pump cover; otherwise, it may cause crushing in the pump body bore.
• Chapter 11 Test procedure:
  • 11.1 Pre-test work:
    • 11.1.1 Check whether all drain valves are closed, and open the pump inlet line valve and return line valve.
    • 11.1.2 Add about 12L of test fluid to the oil tank.
    • 11.1.3 Fully open the pressure regulating valve to ensure that no pressure is generated when the test fluid flows.
    • 11.1.4 Repeatedly lightly press the pump motor "on" and "off" buttons until the test fluid flows back into the oil tank.
    • 11.1.5 The remaining test fluid (the subsequent content of the original text is missing, requires confirmation against the source standard (source-text extraction)).
  • 11.2 Venting stage:
    • 11.2.1 Press the motor "on" button, the vane pump starts running, and the speed is controlled at 1200r/min.
    • 11.2.2 Observe the test fluid in the oil tank to ensure that it is clean, and ensure that the test fluid returning to the oil tank can be seen to contain no air.
  • 11.3 Break-in stage:
    • 11.3.1 Adjust the pump outlet pressure to 2.1MPa.
    • 11.3.2 Within 1h, carry out heating through 6 of 10min steps, while increasing the pump outlet pressure. The pressure levels are respectively 2.1MPa, 4.1MPa, 6.2MPa, 6.9MPa, 10.3MPa (the original text "10 SMPao" is suspected to be source-text extraction noise, requires confirmation against the source standard (source-text extraction)) and 12.4MPa. During the heating stage, the pump inlet temperature will rise; when this temperature rises to within (the original numerical value is missing, requires confirmation against the source standard (source-text extraction)) of the control temperature, begin applying the heat exchanger to cool the test fluid. Note: If (the original content is missing, requires confirmation against the source standard (source-text extraction)) is heard when the pump is heating up, the machine may be stopped, and the pump cover screws tightened with 0.56 N·m torque in the manner described in 10.4.4, thereby reducing (the original content is missing, requires confirmation against the source standard (source-text extraction)).
    • 11.3.3 Determine the pump speed (the subsequent content of the original text is missing, requires confirmation against the source standard (source-text extraction)).
    • 11.3.4 If the pump (the content of the original text is missing, requires confirmation against the source standard (source-text extraction)) temperature and flow rate meet the test conditions, adjust the pump outlet pressure to an accuracy of 13.8MPa. If the pressure fluctuates abnormally or jumps, or if the pressure regulating valve has abnormal noise or vibration, stop the test, re-inspect the pump and safety (the source safety instruction is truncated after its first character, requires confirmation against the source standard (source-text extraction)).
  • 11.4 Test run:
    • 11.4.1 Record the time or adjust the system timer to zero, and determine this time as the official test start time. Note: It is recommended to monitor the test conditions during the first few hours of the test to ensure test stability. A continuous decrease in flow rate indicates internal leakage due to wear of the port plate or misalignment of the pump core.
    • 11.4.2 Run continuously without interruption according to the following test conditions 100h:
      • Pump outlet pressure: 13.8MPa ±0.3MPa;
      • Pump speed: 1200r/min ±60r/min;
      • Pump flow rate: >15.0L/min;
      • Temperature:
        • Water-containing glycol, emulsions and other water-based fluids: 66℃±3℃;
        • 40℃ Petroleum-based oils and synthetic oils with viscosity equal to or lower than 50.6mm²/s: 66℃±3℃;
        • All other petroleum-based oils and synthetic oils: 80℃±3℃.
  • 11.5 Restart the test:
    • 11.5.1 Replacing the stator and vanes during the test is not allowed. If the flow rate of the test fluid drops to 15.0L/min or lower, if the system pressure cannot be maintained, or if there is excessive noise and leakage, terminate the test.
    • 11.5.2 If the loss of flow rate causes the test to be terminated early, it is permitted to replace the port plate and reassemble other components. Report the port plate failure.
    • 11.5.3 Restart the test according to the procedure in clause 11.3.
    • 11.5.4 When the test parameters again meet the test conditions, the test may continue, the timer starts timing, and the cumulative operation is 100h.
  • 11.6 Test shutdown:
    • 11.6.1 Depressurization: After the test is completed, slowly rotate the pressure reduction knob, fully open the pressure regulating valve, so that the test pump outlet pressure drops to 0.3MPa (the original text "0.