HPC/TSC - 300/1K - Universal Coolant Pump Head/Motor - Component Replacement

Introduction

This procedure tells you how to replace a 300/1k psi pump head or motor, cable, or pump head coupling in each of these systems:

High-Pressure Coolant (HPC) - Lathe
Through-Spindle Coolant (TSC) - Mill

This illustration shows each coolant pump type that is in this procedure:

Lid-mounted HPC, TSC pump assembly [1]
HPC, TSC pump with stand assembly [2]
HPC, TSC Auto-Clean pump with stand assembly [3]

This document applies to the following service kits:

93-1525C QTY: 1 (OPTIONAL) PUMP, HPC/TSC-300
93-2589C QTY: 1 (OPTIONAL) PUMP, HPC/TSC-1K
93-2379 QTY: 1 (OPTIONAL) MOTOR, HPC/TSC-300 FIELD INSTALL KIT
93-2595 QTY: 1 (OPTIONAL) MOTOR, HPC/TSC-1K MOTOR FIELD INSTALL KIT
76-2214 QTY: 3 CRIMP WIRE NUT 22-14 NYLONNAL (NEEDED IF REPLACING CABLE)
93-2914A QTY: 1 PUMP SPLINE CONVERSION KIT (NEEDED IF COUPLING PRESSED ONTO PUMP)
93-4195: COOLANT GEAR PUMP COUPLER CONVERSION KIT

Coolant Pump - Disassembly - HPC, TSC 300/1K

1

Disconnect the power cable for the motor. Remove the pump assembly from the coolant tank to let the coolant drain.

If you must replace the motor and the cable, or if the new cable is not compatible with the machine:

Remove the cable [1] from the old motor.

Remove the (2) screws [3] and cover [2] from the new HPC, TSC MOTOR [B].

Remove the cable from the new HPC, TSC MOTOR [B].

Install the cable [1] from the old motor to the new HPC, TSC MOTOR [B].

Connect the old cable to the motor. Use the (3) CRIMP WIRE NUTS [C]. Use crimp pliers and wire strippers to correctly connect the cable.

2

To replace a pump head or motor that is lid-mounted:

Remove these parts:

(4) socket head cap screws [2] and the motor [1]
If you only need to replace the motor [1], replace it now. If no other parts need to be replaced, the procedure is complete.
coupler [3] and (4) socket head cap screws [4]
(2) compression fittings [5] and pump head assembly [6]
(2) steel tube assemblies [7]

Refer to the "Pump Head Coupling Variations" section end of the document for procedure details on your particular pump/coupling/motor combination.

Note: Steel tube assemblies do not need to be removed if replacing the pump head coupling

3

To replace a pump head or motor that has a stand:

Remove these parts:

(4) socket head cap screws [2] and the motor [1]
If you only need to replace the motor [1], replace it now. If no other parts need to be replaced, the procedure is complete.
(4) button head cap screws [8] and the filter housing [9]
coupler [3] and (4) socket head cap screws [4]
(2) compression fittings [5] and pump head assembly [6]
(2) steel tube assemblies [7]

Refer to the "Pump Head Coupling Variations" section end of the document for procedure details on your particular pump/coupling/motor combination.

Note: Steel tube assemblies do not need to be removed if replacing the pump head coupling

4

To replace a pump head or motor on a system that has the auto-clean filter:

Remove these parts:

(2) button head cap screws [2] and (2) pump stand covers [1]
air cylinder [5] (Turn counterclockwise to remove.)
intake tube assembly [7], vacuum switch assembly [8], and brass fitting [9]
steel fitting [10], (4) button head cap screws [11], and intake filter assembly [12]
(4) socket head cap screws [4], coupler [3], and pump head assembly [6]

Refer to the "Pump Head Coupling Variations" section end of the document for procedure details on your particular pump/coupling/motor combination.

Note: Steel tube assemblies do not need to be removed if replacing the pump head coupling

5

Remove these parts:

(2) 90 degree tubes [3]
If you only need to replace the pump head, proceed to Coolant Pump Head/Motor - Replacement section.
(4)socket head cap screws [2]
motor [1]

Refer to the "Pump Head Coupling Variations" section end of the document for procedure details on your particular pump/coupling/motor combination.

Note: Steel tube assemblies do not need to be removed if replacing the pump head coupling

Coolant Pump Head/Motor - Replacement - HPC, TSC 300/1K

1

Install the new HPC, TSC PUMP HEAD [A] and the new HPC, TSC MOTOR in the opposite sequence that they were removed.

Note: For system with auto filter, refer to previous step 4-5 to assemble the auto-clean filter.

Leave the socket head cap screws [2] hand tight. Operate the pump for few seconds to allow the motor to float in. Turn off the pump and torque the motor mounting bolts gradually in criss-cross pattern.

Re-install the coolant pump assembly. Run the coolant pump to test for leaks and correct pressure.

Pump Head Coupling - Flexible Coupling Replacement

This section to be used with 93-4195: Coolant Gear Pump Coupler Conversion Kit . This kit is compatible with the following coolant pumps:

93-1525C: PUMP, HPC/TSC-300
93-2589C: PUMP, HPC/TSC-1K

Note: This procedure requires T-0184: Gear Pump Coupler Spacer Tool

1

Install new gear coupling:

Turn motor so that surface with shaft is facing upward.

Tap new key into place on motor shaft [1].

Place spacer flush against motor. [2] Press new coupler onto motor shaft, with serrated hole facing away from motor.

Tighten set screw onto motor shaft and torque to 80 in lbs (9 Nm). [3]

2

Place lid or pump mount stand on top of motor.

Bolt pump mount plate onto pump head assembly [1]

Place new spacers and pump mount assembly on top of new coupler. [2]

Use new screws and nuts to secture pump mount plate to spacers [3]

Tighten set screw onto pump shaft and torque to in lbs (9 Nm).

Reassemble any further hardware and parts in the opposite order that they were removed. See steps above for more information.

Pump Head Coupling Variations

This section to be used with kit 93-1525B (TSC/HPC 300) OR 93-2589B (TSC/HPC 1K)

NOTE: If your existing pump has the coupling pressed onto the pump head shaft, you must also order kit 93-2914A to convert your pump assembly to the current style.

NOTE: If your existing pump has a floating coupling with a keyway on one side and a spline on the other side, you must also order 20-7846B to convert your pump assembly to the current style.

1

When the pump head is removed from the pump assembly, examine it to see which style coupling it has:

A) Coupling pressed onto the pump head shaft

B) Slip fit coupling with spline on pump head side and key on motor side

C) Coupling sweat-fit onto motor shaft

D) Set screw spline coupling

2

Coupling Pressed Onto the Pump Head Shaft

Discard the old spacers, screws, washers, and mounting plate. These will all be replaced with parts from kit 93-2914. Use the new screws, washers, spacers, and mount plate to install the replacement pump head into the assembly.
Remove the motor from the pump assembly and clean the shaft with a rag. Use scotchbrite and/or lightly stone to remove any burrs or dings on the shaft.
Heat must be applied to replacement coupling from kit 93-2914 [1] to fit on the motor shaft [2]. Due to the possibility of variation in motor shaft sizes, it is necessary to get the coupler extremely hot to avoid it sticking on the motor shaft before it is fully seated.
Using a timer, set the non-splined end of the coupling on a hot plate set to 1000F for 30 minutes.
Do not use a motor spacer when installing the coupling. The motor shaft will bottom out inside the coupling when it is fully seated.
Apply red grease onto the pump head splines and reassemble the pump assembly.

3

Slip Fit Coupling with Spline on Pump End and Key on Motor End

Discard the old slip-fit coupling and motor shaft key. Remove the motor from the pump assembly and clean the shaft with a rag. Use scotchbrite and/or lightly stone to remove any burrs or dings on the shaft.
Heat must be applied to replacement coupling from kit 93-2914 [1] to fit on the motor shaft [2]. Due to the possibility of variation in motor shaft sizes, it is necessary to get the coupler extemely hot to avoid it sticking on the motor shaft before it is fully seated.
Using a timer, set the non-splined end of the coupling on a hot plate set to 1000F for 30 minutes.
Do not use a motor spacer when installing the coupling. The motor shaft will bottom out inside the coupling when it is fully seated.
Apply red grease onto the pump head splines and reassemble the pump assembly using the replacement pump head and original hardware.

4

Coupling Sweat-Fit onto the Motor Shaft

Replace the old pump head with the new pump head [1], re-using all original hardware. Re-use coupling.
Apply red grease to the pump head shaft spline teeth before assembly.

5

Set Screw Spline Coupling

Discard the old spacers, screws, washers, and mounting plate. These will all be replaced with parts from kit 93-2914A. Use the new screws, washers, spacers, and mount plate to install the replacement pump head into the assembly.
Use the coupling [1] from the 93-2914A kit, slide it onto the shaft with the threaded holes lined up to the key way [2] on the shaft.
Thread the set screws (44-0078)[3] in until they sit on the bottom face of the key way.
Apply red grease to the pump head shaft splines and reassemble the pump assembly.

Reference

Refer to the TSC-300/1K - Troubleshooting Guide CHC and HPC-300/1K - Troubleshooting Guide NGC for troubleshooting information.