Continental Hydraulics PVX Series User manual

1
SERVICE MANUAL
PVX Series
Vane Pumps
“A” Design Series
CAUTION – Before performing any service
operation on any PVX Vane Pump, be sure
that all pressure has been relieved from
BOTH SIDES of the system.
CAUTION – Before performing any service
operation on any PVX Vane Pump, discon-
nect or lock off power supply.
CAUTION – Before manually actuating any
PVX Vane Pump, be sure that any resulting
machine function will not endanger persons
or equipment.
PRODUCT IDENTIFICATION
Each PVX Vane Pump has a Model Code stamped
on its nameplate. See Figure 1 for the location of the
Model Code.
This Service Booklet applies to products with
Ordering Codes like the sample in Figure 2.
Figure 2
Figure 1
SYSTEM REQUIREMENTS
FLUID RECOMMENDATIONS - Use premium quality
hydraulic fluids which fall within the viscosity ranges
listed below, at normal operating temperature. Fluids
containing anti-wear additives are not required, but
recommended and when used may extend the life of
system components.
FLUID VISCOSITY
Pump Optimum
Model Operating Viscosity
PVX-8 150 to 250 SUS (32 to 54 cSt)
PVX-11/15 150 to 250 SUS (32 to 54 cSt)
PVX-20/29/36 200 to 300 SUS (43 to 65 cSt)
PVX-46/60/75 200 to 300 SUS (43 to 65 cSt)
FLUID TEMPERATURE - Pump reservoir (bulk) fluid
temperature should not exceed 130° F. (54° C.).
Always select fluid for optimum viscosity at operating
temperature. In no instance should fluid temperature
exceed 160° F. (71° C.).
FILTRATION - For increased component life, fluid
contamination should not exceed 16/13 per ISO/DIS
4406 “Solid Particulate Contamination Code”.
CRITICAL SHAFT ALIGNMENT - PROPER SHAFT
ALIGNMENT IS NECESSARY TO MINIMIZE
EQUIPMENT NOISE, VIBRATION AND SHAFT SEAL
WEAR. Align to less than .006 inches (0.152 mm), as
shown in Figures 3 and 4.
Two precision dial indicators must be used to insure
proper alignment in vertical, horizontal, and parallel
planes.
Coupling halves can be either engaged or disen-
gaged. If disengaged, the outside diameter of the
pump coupling must be smooth and machined true in
respect to the coupling bore.
Proper alignment is achieved when neither indicator
varies more than 0.006 inch (0.152 mm) during one
complete shaft revolution.
Electric Motor
Shaft
Dial Indicators
Figure 3
Basic Pump
GPM
Pressure
Rotation
Seal Type
Mounting
Shaft
Tandem
Control Option
Voltage
Design Letter
PVX-75B-_ _ _ _-P-_ _ _ _ _ _ _ _ _ _-A
MODEL
CODE: PVX- 75B 00-00-P-00 00 00 00 00-A
DATE:
P/N:
V =
Pmax = 3000 psi, 210 bar
IN3/REV. CM3/U
Model Code

2
One indicator rides on the inside face of the pump
coupling. Measuring parallel offset alignment, as in
Figure 4, Proper alignment is achieved when neither
indicator varies more than 0.006 inch (0.152 MM) dur-
ing one complete shaft revolution.
CAUTION - THE COUPLING SELECTED
SHOULD PROVIDE A CLEARANCE FIT ON
THE PUMP AND MOTOR SHAFTS.
Never use couplings with interference or
sweat fits. Do not press jaw coupling hub together
tightly. Allow air gap between hub and insert to pre-
vent end thrust into pump rotor, which will damage
the pump. No external forces (other than rotational)
should be applied to the shaft.
INSTALLATION
Careful attention to the following installation require-
ments will assure satisfactory operation of your PVX
hydraulic pump. The pump should only be installed
by qualified personnel. Please read this bulletin care-
fully for detailed steps to install this equipment
1. REMOVE ALL PLASTIC PROTECTIVE CAP
PLUGS FROM COMPONENT BEFORE
INSTALLATION.
2. Prior to installation, pour a small amount of clean
hydraulic circuit fluid into the pump inlet port and
rotate the pump shaft by hand in the direction indi-
cated by the arrow cast into the pump body (all
PVX pumps rotate from thrust block to compensa-
tor). This insures lubrication at initial start-up.
3. Mount the pump and drive motor to a rigid base not
more than three feet above the fluid level.
4. Align the pump shaft to within 0.006 inches (0.152
mm) Full Indicator Movement (F.I.M.) of the motor
shaft, as in one of the two procedures outlined on
the cover page of this bulletin.
5. Carefully connect the inlet, outlet and case drain
plumbing to the pump. Do not force hard piping to
align with the pump ports. This may pull the pump
out of alignment with the motor.
The inlet line must be plumbed full size to within
three inches of the bottom of the reservoir.
PVX Models: Case flow on all PVX pumps exits
through the port located on the pump body. PVX
8/11/15 models also have an external shock clip-
per drain port located on the compensator that, if
used, must be plumbed. PVX 20 through PVX 75
models have internal shock clipper drains and no
additional plumbing is necessary.
Electric Motor Shaft
Dial Indicators
Figure 4
When installing the case drain plumbing, do not
install the flared portion of any fitting into the case
drain port. Using flared fittings in this manner will
block case drain flow causing shaft seal failure.
The case drain line must also be plumbed to within
three inches of the bottom of the reservoir. The
case drain and main system return lines must be
separated from the pump inlet line by a baffle. The
baffle causes all return flow to travel the length of
the reservoir before re-entering the pump. allowing
for heat dissipation and de-aeration.
6. Fill the reservoir with fluid
INITIAL START-UP
1. Rotate the shaft by hand, in the direction of the
cast in arrow, to insure freedom of rotation.
2. To prime the pump on initial start-up, it is impera-
tive to clear all air from the pumping chambers
first. To do this, open center valving should be
immediately down-stream of the pump outlet port,
which allows all flow (fluid and air) to pass directly
to tank upon start-up. If open center valving is not
included in your circuitry, position your valving to
move cylinders and/or motors in a no-load condi-
tion (75 to 150 psi, 5.2 to 10.3 bar) until the pump
has primed. This “no load” condition is not a pump
compensating pressure value, but is strictly the
result of system resistance.
Another way to clear air from the pumping cham-
bers and prime the pump is to incorporate an auto-
matic air bleed valve in the pump outlet port, or as
close to the outlet port as possible. This valve will
automatically open to allow air to exit to tank upon
start-up. Once all air contained in the pump has
been purged, the valve will automatically close.
3. All PVX Pumps incorporate a volume control.
Continental recommends not reducing the pump’s
output flow by more than 50 percent on start-up
(pump flow is reduced by turning the adjustment
screw clockwise). Once the pump is running, the
volume can be adjusted down to as low as 20 per-
cent of maximum volume at maximum RPM.
4. Jog the motor (no more than 10 revolutions if pos-
sible) and observe the direction of rotation. If the
pump shaft is not rotating in the direction as the
cast arrow on the pump body indicates, reverse
direction of rotation of the motor.
If rotation is correct, continue jogging the motor
until the pump has primed. You will notice a defi-
nite pump tone change and pressure gauge move-
ment when the pump begins to prime. Pressure
adjustments can be made after priming the pump.
5. Pressure adjustments must be made against a
blocked or dead-headed system (cylinders and/
or motors stalled or valving shut off). Increase
pressure by turning the pressure adjustment knob
clockwise. Decrease pressure by turning the pres-
sure adjustment knob counter-clockwise. Pump
pressure setting should be as low as possible, yet
high enough to insure satisfactory machine
performance.
CRITICAL SHAFT ALIGNMENT (Continued...)

3
6. Continental recommends installation of a low resis-
tance check valve to prevent pump reversal on
system shutdown.
Pump Nominal Decrease in Minimum Flow
Model Stroke Flow Per Turn Attainable
In. mm
PVX-8 0.075 1.9 mm 53% <0%
PVX-11 0.080 2.0 mm 50% 0%
PVX-15 0.099 2.5 mm 40% 20%
PVX-20 0.077 1.9 mm 80% <0%
PVX-29 0.106 2.7 mm 56% 8%
PVX-36 0.132 3.4 mm 44% 26%
PVX-46 0.117 3.0 mm 50% 17%
PVX-60 0.150 3.8 mm 40% 34%
PVX-75 0.186 4.7 mm 32% 47%
VOLUME CONTROL ADJUSTMENT
During initial start-up, volume should be at least 50%
of maximum flow.
Only make adjustments to volume control with pump
running at full flow and low pressure while observing
output flow.
PUMP AND SYSTEM SETTINGS
Once the pump is primed and operating properly,
pressure adjustments can be made by placing the
pump in deadhead (blocked circuit, no pump flow)
and turning the adjustment knob on the compensa-
tor. Each pump is factory set to a maximum pressure
of approximately 500 psi (35 bar) for shipment pur-
poses. Turning the adjustment knob in a clockwise
direction will increase maximum pump pressure (com-
pensator setting). Once the desired compensator
setting is reached, tighten the lock nut on the stem to
lock the adjustment in place.
INITIAL START-UP (Continued...) 1. The pump compensator setting should be adjusted
as low as possible, but high enough to meet all
system demands. Keeping the maximum pressure
as low as possible extends the pump life, reduces
the amount of thermal energy generated in the
hydraulic system, and decreases motor energy
consumption.
2. The maximum pressure setting of the pump (com-
pensator setting) needs to be a minimum of 100
psi (7 bar) or greater above the maximum peak
full flow operating pressure in the system. If this
pressure differential is not great enough, pres-
sure spikes in the system can cause the pump to
become unstable or lose output flow.
3. The pressure differential between the maximum
pump pressure and an inline relief valve should
also be set to a minimum of 100 psi (7 bar) or
more. Adjusting the relief valve setting too close
to the pump compensator setting can cause the
pump to become unstable.
4. Your PVX pump is equipped with a volume con-
trol. Adjust the output flow to the desired value.
Adjustments of the volume control should only be
done while the pump is running at full flow and low
pressure. Clockwise rotation of the volume control
adjustment will cause the pump flow to decrease.
Once the desired flow is reached, tighten the lock
nut on the volume control adjustment stem to lock
the adjustment in place.
REPAIR PARTS
When ordering repair parts, please include pump
number and design series. This information will be
found on the pump nameplate as shown in Figure 1
on page 1.
Volume Control
Lock Nut
Bias Cover
Piston
Figure 5

22
4
3
28
9
10
15
14
16
17
6
18
1
21
20
19
PVX-20/36 To rque to 1800 lb/in
(Torque to 204 Nm)
To rque to 850 lb/in
(Torque to 96 Nm)
To rque to 850 lb/in
(Torque to 96 Nm)
To rque to 12 lb/in
(Torque to 1.4 Nm)
724
23
5
13
PVX-46/60/75 To rque to 4970 lb/in
(Torque to 562 Nm)
4
PUMP REBUILD KITS
Model SAE Type SAE “P1” Type
PVX-8 264288 264289
PVX-11/15 264292 264293
PVX-20/29 264296 264297
PVX-36 264300 264301
PVX-46/60 264304 264305
PVX-75 264308 264309
PUMP SEAL KITS
SIZE PART NUMBER
PVX-8 264275
PVX-11/15 264276
PVX-20/29/36 264277
PVX-46/60/75 264278
REFERENCE DESCRIPTION QTY
1 Key 1
2 Rotor shaft 1
3 Vane kit 1
4 Port plate, cover side 1
5 Roll pin 4
6 Thrust block 1
7 Bearing 2
8 Spacer ring 1
9 Pressure ring 1
10 Port plate, body side 1
13 O-ring, ASA-031 / (ASA-035) 2
14 O-ring, ASA-162 / (ASA-265) 1
15 O-ring, ASA-130 / (ASA-229) 1
16 O-ring, ASA-146 / (ASA-146) 1
17 Shaft seal 1
18 O-ring, ASA-332 / (ASA-340) 1
19 O-ring, ASA-110 / (ASA-110) 1
20 O-ring, ASA-111 / (ASA-111) 3
21 O-ring, ASA-143 / (ASA-143) 1
22 O-ring, ASA-157 / (ASA-160) 2
23 Back up ring 2
24 O-ring, ASA-139 / (ASA-152) 2
24 O-ring, ASA-237 / (ASA-237) 1
PUMP
R
o
t
a
t
i
o
n
Pump body viewed
from cover side
Vane tip
orientation is
critical

5
REFERENCE DESCRIPTION QTY
1 Key 1
2 Rotor Shaft 1
3 Vane Kit 1
4 Port Plate, cover side 1
5 Roll Pin 4
6 Thrust Block 1
7 Bearing 2
8 Spacer Ring 1
9 Pressure Ring 1
10 Port Plate, body side 1
– Viton Seal Kit 1
PUMP REBUILD KITS INCLUDE:
REFERENCE DESC., PVX-20/36/(PVX-46/75) QTY
13 O-ring, ASA-031 (ASA-035) 2
14 O-ring, ASA-162 (ASA-265) 1
15 O-ring, ASA-130 (ASA-229) 1
16 O-ring, ASA-146 (ASA-146) 1
17 Shaft Seal 1
18 O-ring, ASA-332 (ASA-340) 1
19 O-ring, ASA-110 (ASA-110) 1
20 O-ring, ASA-111 (ASA-111) 3
21 O-ring, ASA-143 (ASA-143) 1
23 Back Up Ring, Port Plate 2
24 O-ring, ASA-139 (ASA-152) 2
O-ring, ASA-155 (ASA-158) 2
O-ring, ASA-113 (ASA-113) 1
Back Up Ring 1
O-ring, ASA-109 (ASA-109) 1
Back Up Washer 1
VITON SEAL KITS INCLUDE:
(All o-rings durometer rating ≥ 75)
Problem Possible Cause Corrective Action
Excessive 1) Coupling misalignment Align the pump and motor shaft to within .006 of
Noise an inch total indicator reading. The tighter the
alignment, the quieter the pump will be.
2) The continuous pressure is The pumps have been sound tuned at rated
significantly above or below pressure. Consult factory for proper
rated specifications for pressure setting.
210 bar pumps.
3) Fluid in the reservoir is low Fill the reservoir so that the fluid level is well above
and the pump is sucking air. the end of the suction line during all of the
working cycle.
4) Restricted inlet. If a suction strainer is used, check it for
obstructions or dirt. We do not recommend the use
of strainers. They tend to be a leading cause
of cavitation which manifests as excessive noise.
Check also for shop rags left in the reservoir.
5) Air leak in the suction line. Tighten all fittings. If it still leaks, smear grease over
the joints to locate the leak.
6) Suction line has too The suction line should be as short and as
many elbows, or is too long. straight as possible to reduce resistance to flow.
7) Air in the fluid. The return line should terminate below the fluid
level to prevent splashing.
8) Suction line is too small. Suction line should always be equal in size to the
suction port. Never reduce it.
9) Vane does not move freely. Contamination in the fluid, or a burr in the vane slot
can cause a vane to bind up. Proper filtration
and/or deburring of the vane slots is required.
10) Vane is installed incorrectly. The leading edge of the vanes must
be oriented in the direction of rotation.
The leading edge is identified as the low side of
the vane taper.
11) A vane is missing. Make sure all vane slots have a vane in them.
12) Port plates Plates must be installed so that the arrows
not properly installed. point in the same direction as the rotational arrows
on the pump body.
13) Pump rotating backwards. Pump must rotate in direction indicated by arrow
on pump case.
14) Low oil level. Fill reservoir so that oil level is well above the end
of the suction line during the entire work cycle.
TROUBLESHOOTING YOUR PVX PUMP

6
Problem Possible Cause Corrective Action
Excessive Noise 15) Wrong type of oil. See page 1 for oil specifications.
(Ccontinued)
16) Reservoir not vented. Reservoir should be vented through a breather cap
to allow breathing action as fluid level changes.
17) Case drain does not Extend case drain piping so that it terminates
terminate below oil level. below the lowes oil level during machine cycles.
18) Worn Pressure Ring. Replace. This condition is caused by lack of oil,
or by oil that is overheated, contaminated, or too
thin for the application.
19) Two pumps to a common A check valve must be installed in the discharge
manifold. lines of both pumps, to prevent back flow and
surging. Check valves are also required when
accumulators are used in the discharge lines.
Pump will 1) Shaft rotating in When installing a pump, always jog the
not prime the wrong direction. electric motor to check for proper shaft rotation.
Rotation should only be clockwise (right hand) for
PVX pumps.
2) Air leak in the suction line. Make sure all fittings are tight.
3) Pump is air bound. Use an air bleed valve to void the pump and
suction line of air.
4) Fluid level in the reservoir Fill the reservoir so that the fluid level is well above
is too low. the end of the suction line.
5) Volume Control is turned Flow should not be reduced more than 50%
in too far. of maximum. Turn clockwise to restrict flow.
6) Suction port dust plug Remove plug.
left in place.
Pump is unstable 1) Contamination in Thoroughly clean the control orifices
the compensator. and check filtration.
2) Pressure ring is not Control piston should be checked for
moving properly. freedom of movement.
System is too hot. 1) Case drain line is installed The case drain and pump
too close to the inlet should be separated by a baffle in
pump inlet line. the reservoir.
2) Reservoir is undersized. Increase reservoir size, or add a hydraulic
Rule of thumb is a fluid cooler.
minimum reservoir
displacement of 2 to 3
times pump output flow.
3) Pump is operating at Reduce pump pressure to the minimum
higher than required required for the installation.
pressure.
4) Pump is discharging Remove the relief valve. Relief valves are not
through relief valve. required with PVX pumps having a spring or
hydraulic pressure compensator governor. Relief
valves create additional heat energy.
5) Excessive system leakage Check progressively through the system for
through cylinders or valves. sources of leakage.
6) High ambient or radiant heat. Relocate power unit, or insulate against
radiant heat.
7) Low oil level in reservoir. Bring oil up to recommended level. Monitor system
for oil loss.
8) Excessive friction. Make sure fluid is of proper viscosity.
9) Restricted or undersized Clean valves and piping. Check for pinched lines.
valves or hydraulic lines. Use adequate pipe sizes.

7
Problem Possible Cause Corrective Action
Leakage at oil seal. 1) Abrasives on pump shaft. Protect shaft from abrasive dust and dirt.
2) Scratched or damaged Replace oil seal.
oil seal.
3) Coupling misalignment. Re-align the pump and motor shafts. See page 1.
4) Pressure in pump case. Inspect case drain line for restriction. Use only full
size pipe direct to reservoir. PVX-20 to PVX-75,
check for possible check valve failure.
5) Oil too hot. See troubleshooting section “System is too hot.”
Bearing Failure 1) Contaminated fluid. Drain and clean system. Refill with clean fluid
2) Coupling misaligned. Re-align the pump and motor shafts. See page 1.
3) System overheating. See troubleshooting section “System is too hot.”
4) Electric motor shaft end End thrusts on pump shaft will damage bearings.
play, or excessive force Eliminate all end play on electric motors. Couplings
used to install or remove must be a slip fit. Do not hammer or press fit.
coupling.
5) Incorrect fluid. See fluid specifications on page 1.
Pump not 1) Pressure adjustment screw Tighten screw 3 to 5 turns after spring tension
delivering oil. too loose. is felt.
2) Incorrect pump rotation. Pump must rotate in the direction indicated on
case or nameplate.
3) Insufficient oil in reservoir. Fill reservoir so that oil level is well above the end
of the suction line during the entire work cycle.
4) Air leak in suction line. Apply good pipe joint compound, compatible with
hydraulic fluid. Tighten all joints.
5) Oil too thick to prime pump. See oil viscosity specifications on page 1.
6) Maximum volume control Turn volume control screw counterclockwise to
turned in too far. increase delivery.
7) Bleed-off elsewhere in circuit. Check for open center valves, or other controls
connected with a tank port.
8) Pump not properly tuned. Recalibrate pump. See page 2.
9) Pump cover too loose. Replace seals if damaged, and tighten cover bolts.
Pump won’t hold 1) Pump not delivering oil. See troubleshooting section “Pump not
pressure. delivering oil.”
2) Pressure adjustment screw Set adjusting screw to obtain desired
set too low. operating pressure.
3) Worn or damaged Replace compensator.
compensator.
4) One or more vanes stuck Inspect for contaminants or sticky oil.
in slots.
5) Oil bypassing to reservoir. Inspect for open center valves, or other valves open
to reservoir. Assure that relief valve settings are
high enough above system operating pressure.
6) Thrust screw not set properly. Re-set thrust screw.

SYSTEM PLUMBING
1. Use a large diameter suction line with a minimum
of elbows and sharp turns to prevent pump cavi-
tation. As a guide, the size of the suction line
should be as large or larger than the pump inlet
connection. The suction line should be designed
without strainers and should avoid screwed pipe
joints or other poor fitting connections that may
allow air into the fluid. Cavitation and aeration in
the fluid can cause pump damage, instability, and
excess noise.
2. The outlet line should be properly supported to
resist loading from changes in system pressure.
Vibration dampening supports should be located
as close as possible to the pump outlet.
3. The case drain line should be less than 10 ft. [3
meters) long and lead directly back to the res-
ervoir in a location that is always below the fluid
level, but away from the suction line. As a guide,
use a pipe/hose size for the case drain line as
large as the pump case drain connection.
4. Do not use manual positive shut off valves in the
case drain line. Do not use spring loaded check
valves in the case drain line.
5. Restrictions in the case drain line should be
avoided if possible. However, certain swing style
(low mass) check valves and heat exchangers
sized for low pressure drops may be installed in
the case drain line of PVX pumps.
6. Shaft seal failures or reduced shaft seal life
will occur if the maximum case pressure of 10
psig (0.7 bar) is exceeded.
7. Do not connect case drain lines of multiple
pumps into one common line or header. This
can lead to excessive pump case pressures and/
or pressure spikes that could damage the shaft
seal and other internal pump seals. Dynamic
pressure variations in the case pressure can
cause pump instability.
8. Case drain lines and main return line in the reser-
voir should be separated from the pump inlet line
by a baffle system. This insures maximum heat
dissipation and de-aeration of the fluid before re-
entering the pump.
9. To minimize noise and vibration energy that could
be transmitted to the hydraulic system, dampen-
ing flanges and supports should be used between
the pump motor group and the rest of the hydrau-
lic system. When possible, use flexible hoses in
place of hard pipe to prevent unnecessary vibra-
tion. Hoses must eventually be replaced, so the
layout of the hydraulic system should allow for
future hose replacement.
10. It is recommended that a low resistance check
valve be installed in the hydraulic circuit down-
stream of the pump to prevent back-flow through
the pump on system shutdowns. This in-line
check valve can also prevent possible pump sta-
bility problems in circuits with large system capac-
itance (hoses, accumulators, large cylinders, etc.).
PUMP INSTALLATION
11. Thoroughly clean and flush new hydraulic systems
to remove contaminants that could damage your
pump (for filtration requirements, see page 1).
Verify fluid cleanliness prior to pump installation.
Failure to remove contaminants will lead to pre-
mature pump wear and failure.
12. Mount the pump to a rigid base or bell housing,
so it is no more than 3 ft. (1 meter) vertically
above the fluid level in the system reservoir. PVX
pumps can be mounted in any orientation.
13. After the pump has been secured, remove all
plastic protective cap plugs and port covers just
prior to attaching the fluid lines.
14. Carefully connect the inlet, outlet, and case drain
plumbing to the pump while paying special atten-
tion not to introduce any foreign material inside
the pump. Do not force hard or rigid piping to
align with the pump ports. This could potentially
cause misalignment of the pump motor group or
damage the pump internals.
15. On PVX-8/11/15 models, there is an external
shock clipper that can optionally be plumbed to
the tank. The shock clipper can limit the extent of
dynamic pressure spikes that are imposed on the
pump and circuit. It will also minimize pressure
overshoot (spikes) and undershoot to improve
pump stability and pressure decay times. The
connection for the shock clipper is located on the
side of the compensator (control) housing, and if
enabled, must be individually plumbed to tank.
IMPORTANT: When enabled, the shock clipper can
create additional control leakage that may decrease
pump efficiency. On small systems with limited cool-
ing capability, this could result in higher fluid tempera-
tures than desired. In these cases, pump efficiency
will be maximized by not connecting the shock clipper.
16. For PVX-20 through PVX-75 models, the shock
clipper is internal to the compensator design, and
does not need to be externally plumbed.
Continental Hydraulics
5505 West 123rd Street
Savage, MN 55378
Phone: [phone] Fax: [phone]
www.continentalhydraulics.com
Because Continental Hydraulics is continually improving its’ products, specifications and appearance
are subject to change without notice.
Form No. 264443 Rev. 11/08 © 2008, Continental Hydraulics. Printed in U.S.A