Repair Instruction VLR1000 Final Draft

VLR-1000 Repair Instructions
(dito VLR301)
VLR-1000 Index
Page Contents
3 Introduction
4 Required Tools
5 Fastener Torque
Values
6 Health & Safety
7 Before beginning…
8 Disassembly
30 Assembly
Presentation Elmo Rietschle 2 August 2011

VLR-1000 Introduction
The ZEPHYR VLR 1000 is a double-shaft rotary claw

vacuum pump. The claws roll off against each other
contact free and dry. The counter-rotating claws are
synchronized by a pair of gears within the gearbox.
The gears and the bearings are splash-lubricated with oil,
ensuring that the bearings and the gears are sufficiently
lubricated at all permissible speeds.
The gearbox and the compression chamber are separated
from each other by special seals. The gearbox is sealed
from the outside with shaft seals and o-rings. Piston rings
seal the compressor chamber.
This contact-free running claw vacuum pump, the C-VLR
1000, can be operated continuously at any pressure
between atmospheric and an inlet pressure of 200 mbar
abs. A vacuum relief valve is incorporated into the
machine.
VLR-1000 complete with motor

VLR-1000 Required Tools
•Metric hex driver set with ratchet

•Torque wrench, 3/8” and 1/2”
•Metric hex wrench set
•Assorted screwdrivers
•Metric combination wrench set
•Impact wrench (recommended)
•Adjustable pliers
•‘All-Thread’ rod, M12 x 200mm
•Strap wrench
•Soft face mallet
•Anti-seize compound
•Small magnetic dowel pin
•Flange puller set, M8, as shown
in the inset photos (or lifting eyes)
•Aluminum dowel rod, 30mm
(VLR1000) / 15mm (VLR301) dia.

VLR-1000 Fastener Torque Values
The following torque Size Nm lb-ft

values should be followed M4 2.8-3.2 2.0-2.4
unless otherwise indicated
within this instruction M5 5.5-6.4 4.1-4.7
M6 9.6-10.9 7.1-8.0
M8 23-26.1 17-19.2
M10 46-51.5 34-38
M12 79-90 60-70
M14 125-142 92-105
M16 195-218 144-161

VLR-1000 Health & Safety Warnings
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?
Warning: Pinch point. Keep fingers clear.

VLR-1000 Before you begin...
…become familiar with all the text and symbols!

Throughout this manual you will see safety warnings & arrows
• Be sure you have read and understand the warning symbols
from the previous page (4) before proceeding
• Red colored arrows are used to call out a particular part
or location
• Yellow colored arrows are used to show movement or direction
during removal or installation of components
• Position numbers refer to the Exploded View Drawing and
Parts List E880/80 available at: www.gd-elmorietschle.com

VLR-1000 disassembly begins
Using an appropriate lifting device, Remove the screws securing the

the drive motor & flange assembly pos. 71 sheet metal cover. Take
have been removed from the pos. note of screw lengths as they may
55 fan housing. vary by location.

VLR-1000 disassembly
Pos. 74 Cover, front part, being

removed. Remove pos. 37 Eye bolts and set
aside. They will be reused shortly.

Carefully remove the pos. 70

sound hood.
Sound covers completely removed.

Place wooden blocks under pos. 95

Remove 9 screws then pos. 84 Silencer to support its weight and aid in
Support stand back cover by later removal (see page 11).
sliding along the Silencer. Next, remove screw from the pos. 98
Silencer support bracket.

Loosen (only) 6 screws from Now remove the 3 screws along the top and
pos. 47, Cover ‘B‘. Do not replace them with 3 pieces of M12 threaded
remove the screws completely! rod. Then finish removing the remaining
lower 3 screws from Cover ‘B‘.

Push the Silencer/Cover ‘B‘ assembly away

from the compressor housing by sliding it on
Reinstall the 2 eye bolts you removed the wooden supports you placed under the
(pg. 7) and attach your lifting device as Silencer (page 9). Slide only far enough to
shown. expose the bolts connecting the silencer to
Cover ‘B‘.

Remove 4 nuts and separate Remove all fasteners securing

Cover ‘B‘ from the Silencer. the compressor housing to pos.
Carefully set Cover ‘B‘ aside. 87 Bottom Plate.

Also remove the nut attaching

Install lifting eyes onto compressor housing
pos. 64 Rubber foot to pos. 65
as shown. Attach lifting device to lifting
Support channel.
eyes. Raise compressor housing and move
it to a workbench.

In order to
remove the
fan/coupling, you
must first keep
the gears from
turning. To do
so, you may
place a small
magnetic dowel
pin between the
gear teeth
Compressor housing removed.

--------------------------------------
Unscrew center bolt from pos. 59 Inspect Fan for any damage or
Coupling/fan assembly loose blades

Remove screws attaching pos.

Now remove pos. 20 Gear 55 Fan housing to pos. 1
cover. Compressor housing

Block both Rotors with a non-marring

Note the Fan Housing is located device (Ø30 mm) and loosen center
by 2 dowel pins. bolt of both Rotors
On 301 is 14,8 mm
On 501 is 20,05 mm
You may use a soft hammer to Part of the dismantled pos. 46

hit rotors to aide in removing the Conical-clamping element
pos. 46 Conical-clamping
elements. A puller may also be
used.

Use either 2 eye-bolts or a puller Remove pos. 43 Spacer Ring between

to remove Rotors the Rotors and End-covers. Do not
mix-up Rotors and Spacer Rings
between Shafts.

Remove pos. 57 Key from the Remove screws securing

Drive Shaft both pos. 14 Cover & pos.
16 Ring.

There are 2 wavy washers on

each Shaft. Remove them.
Pull Cover and Ring from Gear
Box.

Pos. 19 Sleeve can then be Next remove pos. 18 O-ring

pulled off of Drive Shaft.

Use M8 puller devices, example

Next prepare to remove both shown, to lift the Flanges out of
pos. 33 Flanges out of the housing.
compression chamber by first
removing the fasteners.

You can now see the pos. 28 The Piston ring sleeve can now
Piston Ring Sleeve under the be removed from the Shaft.
flange.

Loosen screws from pos. 31

Bearing Cover. Remove bearing cover.

Using a soft-faced hammer, Remove each Shaft with Bearing

drive the shafts out of the gear assembly from the compressor
box from the motor side. housing. Remove the pos. 32
Shaft seals.

VLR-1000 disassembly is finished
Now you can remove the gears Disassembly is now complete.

and spacer. The compressor housing is
empty and ready for cleaning
and inspection.

VLR-1000 assembly
Place compressor housing in a

horizontal position on wooden
blocks as shown. Preassemble the Drive and Driven
Shafts with Angular Ball Bearings,
Sleeves (pos. 6), O-rings and Keys.
Note: Lightly lubricate the O-Ring with
oil in order to facilitate later assembly.

VLR-1000 assembly
Install both shaft assemblies Preassemble pos. 32 Shaft

into the compressor housing Seal into each of the pos. 31
from the compressor side. Bearing Covers. Note: apply
grease (p/n 7201310000) to
just the sealing lips. Provides
lubrication during initial startup
before the oil arrives.

VLR-1000 assembly
Assemble both Bearing Covers Secure ball bearing at driven shaft

onto the compressor housing. with disc and screw.

VLR-1000 assembly
Attach O-ring and mount Sleeve Final position of sleeve.

onto drive shaft. O-ring should
have a small amount of oil on it
to facilitate next step.

VLR-1000 assembly
Gather pos. 14 Cover, pos. 16 Ring Assemble gathered components

and wavy washers to close access to onto Gearbox with bolts.
the Gearbox.
Torque value = 80 Nm

VLR-1000 assembly
Assemble Coupling Element, Turn compressor housing on

without fan, onto Drive Shaft to end and install both Flanges
aide in completion of the into their final positions.
comressor housing assembly
steps.

VLR-1000 assembly
The Flange on the right is Tighten flange bolts to the

shown already assembled. recommended torque.

VLR-1000 assembly
With Piston Rings installed on Hand-press the Sleeve down

the Sleeve, slide the assembly into its final position. Next, slide
down onto the Shaft as shown. the pos. 43 Spacer Ring onto
Remember to install sleeve, the Shaft.
spacer ring and rotor back on Note: When fully installed, the Sleeve should be
slightly below the surface of the pos. 33 Flange.
the same shaft they were
removed from.

VLR-1000 assembly
Place Rotor onto Shaft. Tighten Remove Rotors. Apply a

with Clamping assembly. Check complete, thin, even coat of Dry
axial tolerance with Feeler Tape & Molybdenum spray to the Rotors
compare to ‘Sa‘ specification and Compression Chamber.
found on the Clearance sheet. Note: Do not coat the backside (Sa side)
of the Rotors!
Correct clearance as required by
resizing spacer ring. Repeat for Also: Do not coat the Cover ‘B‘ sealing
surface.
the other rotor.

VLR-1000 assembly
Fee
l er t
ape
Fe
el
er
ta
pe
Assemble both Rotors, holding

them with an aluminum dowel
as shown. Place recommended
Meanwhile prepare feeler tape in the positions as
Silencer and Support shown, 2 places, between the
stand parts. Rotors.

VLR-1000 assembly
Torque both Rotors, holding Install Gearbox Cover and

them in correct position with the remove coupling element for
Device, as shown. final assembly steps.
Torque value: get from
Clearance sheet.

VLR-1000 assembly
Assemble fan housing onto Gather coupling element parts.

ground unit.

VLR-1000 assembly
Install Fan onto Coupling. Mount Coupling/Fan assembly

and fasten with proper torque.

VLR-1000 assembly
Apply Dry Moly coating to Cover Put ground unit onto bottom-
‘B‘ (mask the sealing surface). plate.
Attach Cover ‘B‘ to silencer inlet
flange.

VLR-1000 assembly
Move Cover ‘B‘/Silencer

assembly into final position
against ground unit.
Attach screws using
proper torque.

VLR-1000 assembly
Assemble support parts such as Install Support stand Covers.

Rubber Foot, etc. Install Motor/flange assembly
onto pump.

VLR-1000 assembly completed
Finish assembly by replacing Pump is ready for testing and

remaining sound covers around painting!
pump body.

Repair Instruction VLR1000 Final Draft

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VLR-1000 Repair Instructions

Presentation Elmo Rietschle 2 August 2011

The ZEPHYR VLR 1000 is a double-shaft rotary claw

Presentation Elmo Rietschle 3 August 2011

•Metric hex driver set with ratchet

Presentation Elmo Rietschle 4 August 2011

The following torque Size Nm lb-ft

Presentation Elmo Rietschle 5 August 2011

Danger of injury if components tip over or fall off!

Danger of crushing injury or equipment damage!

Personal Protection Equipment

‘Right-to-Know’ and MSDS sheets

Warning: Pinch point. Keep fingers clear.

Presentation Elmo Rietschle 6 August 2011

…become familiar with all the text and symbols!

Presentation Elmo Rietschle 7 August 2011

Using an appropriate lifting device, Remove the screws securing the

Presentation Elmo Rietschle 8 August 2011

Pos. 74 Cover, front part, being

Presentation Elmo Rietschle 9 August 2011

Carefully remove the pos. 70

Presentation Elmo Rietschle 10 August 2011

Place wooden blocks under pos. 95

Presentation Elmo Rietschle 11 August 2011

Presentation Elmo Rietschle 12 August 2011

Push the Silencer/Cover ‘B‘ assembly away

Presentation Elmo Rietschle 13 August 2011

Remove 4 nuts and separate Remove all fasteners securing

Presentation Elmo Rietschle 14 August 2011

Also remove the nut attaching

Presentation Elmo Rietschle 15 August 2011

Compressor housing removed.

Presentation Elmo Rietschle 16 August 2011

Presentation Elmo Rietschle 17 August 2011

Remove screws attaching pos.

Presentation Elmo Rietschle 18 August 2011

Block both Rotors with a non-marring

You may use a soft hammer to Part of the dismantled pos. 46

Presentation Elmo Rietschle 20 August 2011

Use either 2 eye-bolts or a puller Remove pos. 43 Spacer Ring between

Presentation Elmo Rietschle 21 August 2011

Remove pos. 57 Key from the Remove screws securing

Presentation Elmo Rietschle 22 August 2011

There are 2 wavy washers on

Presentation Elmo Rietschle 23 August 2011

Pos. 19 Sleeve can then be Next remove pos. 18 O-ring

Presentation Elmo Rietschle 24 August 2011

Use M8 puller devices, example

Presentation Elmo Rietschle 25 August 2011

Presentation Elmo Rietschle 26 August 2011

Loosen screws from pos. 31

Presentation Elmo Rietschle 27 August 2011

Using a soft-faced hammer, Remove each Shaft with Bearing

Presentation Elmo Rietschle 28 August 2011

Now you can remove the gears Disassembly is now complete.

Presentation Elmo Rietschle 29 August 2011

Place compressor housing in a

Presentation Elmo Rietschle 30 August 2011

Install both shaft assemblies Preassemble pos. 32 Shaft

Presentation Elmo Rietschle 31 August 2011

Assemble both Bearing Covers Secure ball bearing at driven shaft

Presentation Elmo Rietschle 32 August 2011

Attach O-ring and mount Sleeve Final position of sleeve.