This document is a service manual for the Permco Bushing Series, covering the maintenance, disassembly, and assembly of their high-pressure hydraulic gear/vane pumps and motors, flow dividers, and intensifiers. The manual provides detailed instructions and specifications for servicing these units, which are available in a wide variety of sizes and configurations to suit various application needs.

Function Description:

The Permco Bushing Series encompasses a range of hydraulic components including pumps, motors, flow dividers, and intensifiers. These devices are designed to operate under high pressure, converting mechanical power into hydraulic power (pumps) or hydraulic power into mechanical power (motors). Flow dividers distribute hydraulic flow, while intensifiers increase hydraulic pressure. The manual specifically focuses on the Bushing Series, indicating a design that utilizes bushings as critical bearing surfaces, which are integral to the performance and longevity of the units.

Important Technical Specifications:

The manual provides several technical specifications crucial for service and assembly:

Bushing Removal and Insertion Kits: Specific kits (T-1194, T-1188, T-1175, T-1199) are listed for different series (124, 197, 257, 360), indicating the need for specialized tools for proper bushing handling.
Bushing Dimensions: Detailed diagrams and tables provide critical dimensions for bushing removal and insertion, including "A" DIA., "B" DIA., "C" DIA., "D" DIA., and "E" dimensions. These dimensions are essential for selecting the correct tools and ensuring proper fit. For example, for the 124 Series, the "A" DIA. for bushing removal is 0.920/0.940, and for insertion, it's 1.307/1.312.
Motor Seal Expansion Sleeve Dimensions: A table specifies dimensions (A, B, C Dia.) for different series (124, 197, 257, 360) related to the motor seal expansion sleeve, which is crucial for proper sealing.
Torque Specifications: For the final assembly step (Step 18), the manual provides torque values for the drive shaft end cover fasteners. These vary by series and whether the unit is a pump or motor:
- 124 Series: 120 ft. lbs (Pump), 120 ft. lbs (Motor)
- 197 Series: 200 ft. lbs (Pump), 200 ft. lbs (Motor)
- 257 Series: 200 ft. lbs (Pump), 200 ft. lbs (Motor)
- 360 Series: 250 ft. lbs (Pump), 450 ft. lbs (Motor)
Bushing Install Diagrams: Specific diagrams (P124/M124, P197/M197, P257/M257, P360/M360) illustrate the correct orientation and placement of bushings, including "BUTT JOINT" and "LUBE GROOVE" locations, and specify that bushings must be flush to slightly below the surface. For P197 series, bushings with lube grooves and butt joints are shown for optimum performance, and may be installed per M197 diagram. For P360/M360, the bushing OD chamfer/lead-in is down and square corner must be flush to slightly below surface.
Fluid Type and Temperature Conditions: The manual recommends using compatible mineral base, water glycol, and invert emulsion fluids. It also specifies normal operating temperatures (180°F (82°C) for mineral base fluids and 135°F (57°C) for water glycol and invert emulsions). A premium quality hydraulic fluid with a viscosity range of 150-300 SUS (32-65 cSt) at 100°F (38°C) is recommended for optimum performance. The normal operating viscosity range is between 55-1000 SUS (9-220 cSt) with a start-up viscosity not to exceed 2000 SUS (440 cSt).
Minimum Return Line Filter: A Beta 10 rating of 2.2 is required for the system to prevent contamination.

Usage Features:

The Permco Bushing Series units are designed for high-pressure hydraulic applications. While the manual focuses on service, it implicitly highlights features that contribute to their robust operation:

Multiple Configurations: The availability of various sizes and configurations (pumps, motors, flow dividers, intensifiers) allows for broad application in diverse hydraulic systems.
Bushing Design: The use of bushings as bearing surfaces is a key design choice, influencing the unit's performance, durability, and maintenance requirements. Proper installation of these bushings, as detailed in the manual, is critical for optimal function.
Modular Design: The disassembly and assembly instructions suggest a modular design, allowing for individual components (like end covers, gear sets, shafts, and bearings) to be serviced or replaced, extending the life of the overall unit. This is evident in the "Multiple Sections" and "Single Port End Cover" exploded views.
Outboard Bearing Option: The manual mentions an "Outboard Bearing (Optional)" (Item 2 in the exploded view), indicating that some units can be configured with an additional bearing for enhanced support in certain applications.

Maintenance Features:

The manual is primarily a guide for maintenance, offering comprehensive instructions and guidelines:

Tool List: A specific list of tools (Arbor Press, Bearing Puller, Bushing Removal Kit, Collets, Bushing Installation Kit, Soft Face Hammer, Medium Grit Stone, Oil and Grease, Torque Wrench, Bench Vise, Crayon or Marker, Permatex Aviation Form-A-Gasket #3, Snap Ring Pliers, Lip Seal Install Plug, Motor Seal Expansion Sleeve) is provided, emphasizing the need for specialized equipment for proper servicing.
General Notes for Service:
- Read all instructions prior to disassembly and assembly to familiarize yourself with all steps.
- All areas and tools must be clean, and all parts cleaned with a lintless cloth before assembly.
- All components must be prepared and marked (if needed) for correct rotation.
- Use only genuine Permco parts, as other manufacturers' parts may not fit.
- Refer to bushing diagrams included for each series on pages 9-10.
- Tear down and assembly shown is a P257 2 section pump.
Detailed Disassembly and Assembly Steps: The manual provides step-by-step instructions with accompanying images for both disassembly and assembly, covering critical procedures such as:
- Removing fasteners and end covers.
- Extracting thrust plates, gear sets, connecting shafts, and bearing carriers.
- Inspecting bushings and removing retaining rings and outboard bearings.
- Removing the shaft seal.
- Cleaning and deburring components.
- Applying Permatex Aviation Form-A-Gasket #3 and flushing the seal into the bore.
- Installing bushings with the correct orientation and flushness.
- Installing spirolock retaining rings and start pins.
- Greasing gasket seals and placing rubber elements in grooves.
- Squiring oil into bushings and on thrust plates.
- Positioning bearing carriers and connecting shafts.
Guide for Replacing Parts: Specific guidelines are given for replacing worn components:
- Thrust Plates: Replace if scored, eroded, pitted, or discolored from heat.
- Gears: Replace if any scoring on journals is found, or if fretting, nicking, scoring, or grooving of teeth surfaces is present.
- Gear Shafts: Replace if any wear is found in seal area or if any wear on splines or keyway is found.
- Gear Housing: Replace if wear exceeds 0.005" below bore.
- Dowel Pins: Replace if loose in the casting, or if the dowel pin or casting must be replaced.
- Bushings: Replace if scoring, discoloration, or signs of copper showing through. If gear set is replaced, the bushings should also be replaced.
Startup and Break-in Procedure:
- Before startup, unscrew the main relief valve on the circuit.
- Run the pump for two minutes under no load conditions (low pressure, low rpm of 1400 rpm minimum). If everything seems to function properly and no unusual sounds are heard, proceed with the break-in procedure.
- The testing procedure involves loading and unloading the unit to prevent contamination of the bushings and bushing journals.
- A table provides recommended run times and corresponding pressure for break-in, starting from 0-15 seconds at 0 psi and gradually increasing to 241-255 seconds at 4000 psi.
Online Support: Permco offers 24/7/365 online support via their website (www.permco.com) and email (support@permco.com), along with a phone number for assistance.

This comprehensive manual ensures that technicians can effectively maintain, repair, and optimize the performance of Permco Bushing Series hydraulic components, extending their operational life and ensuring reliable function in high-pressure applications.

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