Continental Hydraulics PVR1 Series User manual

1
Form No. 253585 Rev. 04/19
SERVICE MANUAL
PVR1 Manifold Series Pump
Installation, Start-Up, Operating Instructions, Parts Pages, Repair Procedures
“I” Design Series
Basic Pump
Pump Size
Pressure
Seal Type
Mechanical Options
Design Letter
PVR1- _ _ _ _ - RM - _ - _ _ - I
Figure 1
Figure 2
SAVA GEMNU.S.A 55378
PVR1-
RATINGS
rrpm
vIN3/
r
ppsi
pbar
ml
/
r
6B10 - RM - 0 - 1 - I
Model Code
CAUTION -Before performing any service
operation on any pump, be sure that all
pressure has been relieved from BOTH
SIDES of the system.
CAUTION -Before performing any service
operation on any pump, disconnect or lock
off power supply.
CAUTION - Before starting pump, be sure
that any resulting machine function will not
endanger persons or equipment.
PRODUCT IDENTIFICATION
Each pump has a Model Code stamped on its
nameplate. See Figure 1 for the location of the
Model Code.
This service manual applies to products with Ordering
Codes like the sample in Figure 2.
INSTALLATION
NOTE THESE CHANGES: Design Series
“A” thru “G” used a #406 woodruff key
nominally 1/8 inch (3.2 mm) wide. Design
Series “H” and later use a common 3/16 x 3/16 x 1
inch square key. When replacing older pumps with a
newer one, it will be necessary to either install a new
coupling half with a 3/16 inch keyway or machine the
existing keyway. Also, the pressure adjustment screw
is 3/4 inch (19.1 mm) longer. Check dimensions of
existing installation to make sure there is sufficient
clearance for the adjustment screw.
PUMP DRIVE AND MOUNTING
When mounting the pump and motor, care must be
taken to align the pump and motor shafts within .003
T.I.R. Direct inline through a jaw type/flexible web
coupling is recommended for all Continental pumps.
Tire-type flexing elements and chain-type drives are
not recommended. With belt drives, please consult
factory.
To avoid axial and radical end loading of the pump
shaft, do not couple the pump and motor shafts
rigidly. Allow freedom at the coupling for the two
shafts to ride independently.
To prevent end loading, the space between the pump
and motor shaft ends should be 1/2 inch (12.7 mm)
for PVR1 pumps, or as the coupling manufacturer
specifies.

2Form No. 253585 Rev. 04/19
PIPING AND RESERVOIR
The pump should be mounted with a minimum
number of elbows or fittings. The pump suction
should be at least one (1) inch (25.4 mm) tube/pipe
for PVR1 pumps. For any system and combination of
piping except High Water Based Fluids (HWBF), the
vacuum at the pump inlet must not exceed seven (7)
inches of Mercury, (5 inch Hg. for fire resistant fluids).
HWBF Pumps are to have a positive inlet head in the
range of 0.5-inch Hg. to 20 inch Hg.
Piping should be done with pickled pipe or seamless
tubing free of dirt and scale. Do not use galvanized
or other pipe that tends to flake off.
A 100-mesh screen (60 mesh for fire resistant and
HWBF) should be used on the pump suction line.
The screen should be located approximately two (2)
inches (50.8 mm) from the bottom of the tank. All
lines returning oil to the tank should discharge at least
two (2) inches (50.8 mm) below the minimum oil level
and should be separated from the pump suction area
by means of a baffle. These lines should also include
a 10-micron return line filter, with the exception of the
case drain line.
The pump case drain should be connected directly to
the tank. Pressure in excess of 10 psi (0.7 bar) in the
case drain line can result in shaft seal leakage. It is
recommended that the case drain be returned to the
tank by a separate 3/8-inch (9.5 mm) line.
STARTUP PROCEDURES
The following instructions apply for initial start-up of
the hydraulic pump. After an extended shutdown
period, start with item 5.
CAUTION - Never start a new pump installa-
tion against a blocked system.
1. Check the nameplate for model number and rpm.
The arrow on the pump casting and/or nameplate
indicates direction of rotation.
2. Pump suction line should extend below the lowest
point of oil level but not less than two (2) inches (50.8
mm) above reservoir bottom.
3. The pump and motor shafts must be aligned within
.003 inches (.08 mm). (See Pump Drive and Mounting
directions above for restrictions).
4. Connect the case drain directly to tank (or to a
heat exchanger if the pump will be deadheading for
long periods of time during operation) using a full-size
line corresponding to the case drain in the pump or
manifold. If connected to a heat exchanger, the case
drain line should be protected with an 8 psi (0.55 bar)
maximum relief valve in parallel with the heat
exchanger. No other return lines should be connected
in common with the case drain return.
5. Rotate pump and motor by hand to insure free
rotation.
6. Set the machine controls to open the circuit and
allow free flow from the pump back to tank or connect
the pump outlet line directly to tank. Jog the motor on
and off several times (on two seconds; off three
seconds) until the pump is primed. Check pump for
proper direction of rotation during the jogging.
7. After the pump has been primed, run it for several
minutes at lower than normal pressures with an open
or intermittently open system which permits oil flow.
This will purge entrapped air from the pump and
system.
8. Neither volume adjustment nor pressure
adjustment should be adjusted until the pump has
been primed and running, and air is purged.
9. After air has been purged from the system, the
system can be closed and the pump adjusted to the
required operating pressure.
10. If necessary, the volume adjustment can be
adjusted to limit maximum output to the desired
amount.
11. When replacing pumps, the suction screen in the
reservoir must be removed and thoroughly cleaned.
Also, the suction line from the reservoir to the pump
must be flushed inside and out to remove any
contaminants. Pieces of metal from a damaged pump
can back up into this line. If they are not removed,
they will be drawn into the new pump and destroy it.
Start unit by using proper pump start-up procedures
as previously stated.
CAUTION - If both pressure and volume
controls are supplied on the pump, the
pressure should be adjusted before the
volume. Volume should be adjusted at minimum
pump pressure or at deadhead. Stop adjusting the
volume screw when pressure begins to drop.
OPERATION
Pressure Control Adjustment
All pumps (except those with special volume or
pressure requirements) are adjusted to reduced
pressure before shipment and must be readjusted to
the required system pressure after installation and
start-up.

3
Form No. 253585 Rev. 04/19
The pressure adjusting screw is located at the end
face of the compensator chamber. See parts page
item number 30. The adjusting screw has a right
hand thread; clockwise adjustment of the screw
increases the pressure; counterclockwise adjustment
reduces the pressure.
A pressure gauge located at the pump must be used
when making adjustments to ensure the pressure
settings do not exceed limits specified for the
particular pump or maximum system pressure.
Make all pressure settings with the pump operating
against a closed circuit, that is with the output of the
pump blocked, and then check pressure throughout
the pump flow range.
Volume Control Adjustment
Adjust volume at minimum pump pressure or at pump
deadhead. The volume adjusting screw is directly
opposite the pressure adjusting screw, see parts page
item number 55. The adjusting screw has a right
hand thread, turning the screw clockwise decreases
the maximum volume, turning the screw
counterclockwise increases the maximum volume.
Pumps are set at maximum rated volume at the
factory unless otherwise specified.
Stop adjusting the volume screw when pressure
begins to drop. See Sales Catalog for complete
pump performance specifications.
ADJUSTMENT PROCEDURES
To adjust the maximum output volume, use the
following steps:
1. Set the pump at minimum pressure.
2. Hand-tighten the volume screw until it touches the
pressure ring. NOTE: The pump should be at full flow
for this step.
3. See Pressure and Volume Adjustment Sensitivity
chart below.
4. Deadhead the pump, then turn the volume screw
the proper number of turns to obtain the flow desired.
5. Return pump to flow condition and check flow rate.
If the output flow is incorrect, switch pump to
deadhead and readjust per above.
CAUTION - Turning the maximum volume
control in too far can force the pressure ring
over-center and destroy the pump.
PRESSURE and VOLUME ADJUSTMENT SENSITIVITY
PUMP SIZE 4B 6B 8B
PRESSURE CODE 10 15 03 06 10 03 06 10
PRESSURE Press Change/Turn psi (bar) 255 (17.8) 270 (18.6) 115 (7.9) 210 (14.5) 240 (16.5) 115 (7.9) 210 (14.5) 240 (16.5)
ADJUSTMENT Max.Torque ft./lbs.(kg/m) 4.0 (0.55) 6.0 (0.83) 1.4 (0.19) 2.6 (0.36) 4.0 (0.55) 1.4 (0.19) 2.6 (0.36) 4.0 (0.55)
VOLUME Flow Change/Turn gpm (lpm) 3.4 (12.5) 4.6 (17.4) 4.6 (17.4)
ADJUSTMENT Min. Flow Adjust. gpm (lpm) 1.25 (4.7) 1.25 (4.7) 1.25 (4.7)
Max. Torque ft./lbs. (kg/m) 2.5 (0.34) 1.0 (0.14) 1.0 (0.14)

4Form No. 253585 Rev. 04/19
40
45
45
46
46
55
19
24
21
1
11
9
10
30
8
25
20
23
4
6
59
16
58
39
3
5
15
80
21
2
66
22
713
17
18
67
31
4B Only
22
34 32
33
24
3
2
66 67
PVR1 PARTS DRAWINGS
For PVR1-6B, Code 13
Tandem Mounting Only

5
Form No. 253585 Rev. 04/19
ITEM CODE PART DESCRIPTION QTY
NO. NO. REQ’D
1 550173 Pump Body 1
2 508943 Cover 1
2 6B; Code 13 550833 Cover 1
3 407929 Rotor Shaft 1
3 4B 407930 Rotor Shaft 1
3 6B; Code 13 550834 Rotor Shaft 1
4 4B 550111 Port Plate 1
4 6B 049944 Port Plate 1
4 8B 500598 Port Plate 1
5 550351 Thrust Plate 1
6 4B 114592 Pressure Ring 1
6 6B 112021 Pressure Ring 1
6 8B 123175 Pressure Ring 1
7 4B 250516 Vane Kit 1
7 6B, 8B 250517 Vane Kit 1
8 166620 Spring Seat 1
9 4B10, 8B06 116375 Governor Spring 1
9 4B15, 6B06 116381 Governor Spring 1
9 6B03 116373 Governor Spring 1
9 6B10, 8B10 116376 Governor Spring 1
9 8B03 116374 Governor Spring 1
10 6B03, 8B03 130295 Spring 1
11 4B 114584 Ring Shoe Assembly 1
11 6B 112022 Ring Shoe Assembly 1
11 8B 123174 Ring Shoe Assembly 1
13 307257 Teflon Seal Ring 1
15 124194 O-Ring 1
15 Viton 147177 O-Ring 1
16 106739 O-Ring 1
16 Viton 109781 O-Ring 1
17 111891 O-Ring 1
17 Viton 166612 O-Ring 1
18 198295 Soc. Hd. Cap Screw 4
19 252792 Thrust Screw 1
20 250371 Thrust Screw Plug 1
21 163797 Bearing Bushing 2
ITEM CODE PART DESCRIPTION QTY
NO. NO. REQ’D
22 126225 Key (Add 1 - Code 13; 6B) 1
23 004223 Roll Pin 2
24 130795 Lip Seal (Add 1 - Code 13; 1
6B)
25 104617 O-Ring 1
25 Viton 166069 O-Ring 1
30 309977 Pressure Adj. Screw Ass’y. 1
31 4B 255204 Spacer 1
32 6B; Code 13 351087 Seal Retainer 1
33 6B; Code 13 198221 Soc. Hd. Cap Screw 4
34 6B; Code 13 001508 O-Ring 1
39 115787 O-Ring 2
39 Viton 114944 O-Ring 2
40 250058 O-Ring Plug 1
40 Viton 254789 O-Ring Plug 1
45 15, 36 252152 Handwheel (Add 1 - Code 1
1536)
46 15, 36 261323 Spring Pin (Add 1 - Code 1
1536)
55 6, 36 450196 Volume Adj. Screw Ass’y. 1
58 013976 Mounting Plate 1
59 018507 Cover Plate 1
66 309973S Escutcheon 1
66 6B; Code 13 111431S Escutcheon 1
67 250597 Drive Screw 4
80 002586 Dowel pin 2
80 4B 260382 Dowel Pin 2
PVR1 PARTS LIST
WEAR PLATE KIT
Includes Items: 4, 5 and 31 & 80 for 4B
Model Kit No.
4B 251307
6B 251308
8B 251309
ROTATING KIT
Includes Items: 3, 6, 21
Model Kit No.
4B 250758
6B 250760
8B 250759
COMPLETE REBUILD KIT
Includes Items: All Kits Listed & Item 22
Model Kit No.
4B 251310
6B 251311
8B 251312
SEAL KIT
Includes Items: 13, 15, 16, 17, 24, 25, 39
& seals for items 40 or 55
Model Kit No.
All Buna-N 250454
All Viton 250455
VANE KIT
Includes Item: 7
Model Kit No.
4B 250516
6B, 8B 250517
PVR1 KIT LIST (Refer to Drawing and Parts List)

6Form No. 253585 Rev. 04/19
PVR1 PUMP REPAIR PROCEDURES
DISASSEMBLY PROCEDURE
NOTE: Disassembling the pump to
change components, or for any other
reason, may void the warranty. Refer to
Policy Statement and Discounts
Summaries.
Disconnect all power before disassembly!
1. Remove the key (22) in the rotor shaft keyway.
2. Remove the four cover bolts and slide the cover
back far enough on the shaft to break the seal
between the housing and cover to allow the pump to
drain. A small amount of oil may remain in the pump.
3. Remove the cover (2). Take care to avoid damage
to the bearing with the end of the shaft when the
cover is removed.
4. The thrust plate (5) may come out with the cover.
Do not let it drop off the locating pins.
5. Remove the vanes (7) with a long nosed pliers or
tweezers, there is one vane in each slot, 13 vanes
total.
6. Remove the rotorshaft (3) from the pump. Be sure
that the key (22) has been removed from the keyway
so that it will not damage the shaft seals when the
rotorshaft is removed.
7. Turn the pressure adjustment screw (30)
counterclockwise to release the tension on the
governor spring.
8. Remove the pressure ring (6), ring shoe (11),
governor spring (9), spring seat (8) and follower
spring (10).
9. If the lip seals (24) are to be removed they should
be pushed out from the inside of the housing at this
time. Care must be taken not to damage the bearing
bushing (21) in the housing while the lip seals are
being removed. It is recommended that the lip seals
be replaced whenever the pump is disassembled for
maintenance. The seals cannot be reused once they
have been removed.
10. The bearing bushing (21) in the pumps are
assembled with a press fit. If they are to be removed
at this time, the bearing in the housing should be
pressed out from the front. The cover bearing should
be pulled out using an expanding type puller. The
bearings should not be reused once they have been
removed.
11. It is unlikely that further disassembly will be
necessary in order to perform routine maintenance on
the pump.
REASSEMBLY PROCEDURE
1. Clean and inspect parts to determine which parts
are worn enough to require replacement.
2. Assemble the new bearings (21) in the housing
and cover. The bearing OD's should be lubricated
before they are pressed in the bores. Care must be
taken to orient the "split" and the "oil groove" in the
bearing as shown in the illustration below.
3. After the bearings are in place, check to see that
the rotor shaft (3) will fit into the bearings and provide
a smooth turning fit. If the shaft turns hard, the
bearings should be removed and the bore checked
closely for nicks or burrs before pressing in the new
bearings.
4. Check all of the replacement parts for nicks or
burrs and then lubricate them with clean oil before
reassembly.
5. Worn port (4) and thrust plates (5) should not be
reground to clean up the wear surface. If the plates
are ground, the assembly clearance will become
excessive and the seal rings in the thrust plate may
rupture. Replace worn port and thrust plates if
necessary.
6. Assemble the port plate (4) on the locating pins
(23) in the body housing. If the bores are not
concentric, the port plate must be rotated 180° on the
locating pins.
7. Assemble the springs (9 and 10), spring seat (8)
and ring shoe (11), pressure ring (6) and rotorshaft
(3).
8. To assure proper vane assembly, place the vanes
(7) with the beveled edge against the pressure ring.

7
Form No. 253585 Rev. 04-19
9. Install the o-ring (15) into the thrust plate (5) and
the square teflon seal ring (13) on top of it. Stretch
the larger soft seal ring slightly so it clings to the OD
at the cavity. Apply clean oil or STP to the back of
the thrust plate before it is placed on the locating pins
in the cover to help hold the parts together while they
are assembled.
10. Before fitting the cover into the housing, check to
assure that the bore in the thrust plate is concentric to
the bearing bore in the cover. If the bores are not
concentric, the thrust plate must be rotated 180° on
the locating pins.
11. Assemble the cover (2) and thrust plate (5) onto
the housing (1) and align the bolt holes. Rotate the
shaft as the cover bolts (18) are tightened to assure
that the vanes are not cocked.
12. Torque the cover bolts to 50 lbs-ft ±10 lbs-ft. The
shaft should turn by hand when assembly is
complete.
13. Lubricate the ID of the shaft seals (24) and press
them into the housing to the depth shown below.
Note the "lips to the inside" orientation of the seals.
14. Adjust the pressure adjustment screw (30) until it
just touches the spring and then give it one more turn
clockwise.
15. Turn pump upside down. Pour one cup of good
grade hydraulic fluid into the intake port while slowly
rotating the shaft in the direction shown by the
rotation arrow.
16. The pump is now ready to test. Refer to the
start-up procedure in the front of this manual.
.31 (7.87 mm)
.59 (14.99 mm)

Because Continental Hydraulics is continually improving its’ products, specifications and appearance
are subject to change without notice.
Form No. 253585 Rev. 04/19 © 2008, Continental Hydraulics. Printed in U.S.A
Continental Hydraulics
5505 West 123rd Street
Savage, MN 55378
Phone: [phone] Fax: [phone]
www.continentalhydraulics.com