SERVICE MANUAL
Contents
1. 6B 8B 10B 12 550547 Cover 1 17 Viton 144966 O Ring 1 1221 18 198297 Soc Hd Cap Screw 4 2 4B 21 550659 Cover 1 18 4B 21 6B 8B 198301 Soc Hd Cap Screw 4 10B 21 1221 3 407929 Rotorshaft 1 19 252792 Thrust Screw 1 3 4B 407930 Rotorshaft 1 20 250371 Thrust Screw Plug 1 3 4B 12 506066 Rotorshaft 1 21 163797 Bushing 2 3 6B 8B 10B 12 506069 Rotorshaft 1 22 126225 Key 1 3 6B 8B 10B 550325 Rotorshaft 1 23 004223 Roll Pin 3 1221 24 130795 Lip Seal 1 3 4B 21 550326 Rotorshaft 1 25 Buna N 104617 O Ring 1 3 6B 8B 10B 21 550327 Rotorshaft 1 25 Viton 166069 O Ring 1 4 4B 6B 550101 Port Plate Assembly 1 30 309977 Pressure Adj Screw Ass y 1 4 8B 550074 Port Plate Assembly 1 40 Buna N 250058 SAE O Ring Plug 1 4 10B 550280 Port Plate Assembly 1 40 Viton 254789 SAE O Ring plug 1 5 550351 Thrust Plate 1 41 306466 Spring Retainer 1 6 4B 114592 Pressure Ring 1 42 144927 Shim 005 1 6 6B 112021 Pressure Ring 1 43 144928 Shim 0149 1 6 8B 123175 Pressure Ring 1 46 15 36 252152 Handwheel 1 6 10B 251715 Pressure Ring 1 47 15 36 261323 Spring Pin 1 7 4B 250516 Vane Kit Set of 13 1 50 17 350952 Dual Pressure Control Ass y 1 7 6B 8B 10B 250517 Vane Kit Set of 13 1 53 8 9 256508 Flow Control Valve 1 8 306465 Spring Seat 1 55 6 36 450196 Volume Adj Screw Ass y 1 8 6B3L 6B5L 350988 Spring Seat 1 66 307179S Na2. CONTINENTAL SERVICE MANUAL PVR6 Flanged Series Pump Installation Startup Operating Instructions Parts Pages Repair Procedures HYDRAULICS 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 gt gt gt PRODUCT IDENTIFICATION Each pump has an Ordering Code stamped on its nameplate See Figure 1 above for the location of the Ordering Code Form No 265664 Rev 11 08 H Design Series PVR6 ORDERING CODE gt 4B20 RF 0 6 H Figure 1 This service manual applies to products with Ordering Codes like the sample shown below Basic Pump gt PVR6 __ __ RF _ 1 H Pump Capacity AN Pressure Range A Rotation Mounting Fluid Type Port Options Mechanical Options Control Options Design Letter INSTALLATION 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 0 076 mm direct inline through a jaw type flexible web coupling This is recommended for all pumps Tire type flexing elements and chain type drives are not recommended With belt drives please con
3. 13 15 16 17 24 28 30 99 Includes ltems 3 6 amp 21 Includes Items All Kits Listed Here Plus Item 11 Model Kit Number Model Kit Number Model Kit Number Model Kit Number 4B 257094 All Buna N HW 257093 4B 250758 4B 257095 6B 250747 All Viton 250457 4B 21 250815 4B 12 257096 8B06 15 250748 6B 250760 6B 250822 10B10 254911 VANE KITS 6B 12 254763 6B 12 250826 Includes Items 7 6B 21 250817 8B15 250823 Model Kit Number 8B 250759 8B15 12 250827 4B 250516 8B 12 250762 10B 254917 6B 8B 10B 250517 8B 21 250816 10B 12 254918 10B 254912 10B 21 254919 Form No 265664 Rev 11 08 PVR6 PUMP REPAIR PROCEDURES DISASSEMBLY PROCEDURE NOTE Disassembling pump to change components or for any other reason may void the warranty Refer to Policy Statement and Discounts Summaries 1 Remove the key 22 in the rotor shaft keyway 2 A small amount of oil may remain in the pump 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 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 port plate 4 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 ke
4. 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 the required operating pressure 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 should 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 procedure items 1 through 10 CAUTION If both pressure and volume modifications are supplied on the pump the pressure should be adjusted before the volume Volume should be adjusted at minimum pump pressure or at deadhead Sto
5. cations and appearance are subject to change without notice 8 Form No 265664 Rev 11 08 O 2008 Continental Hydraulics Printed in U S A
6. cifications 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 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 output flow is incorrect switch pump to deadhead and readjust per above CAUTION Turning the maximum volume A control in too far can force the pressure ring over center and destroy the pump PRESSURE and VOLUME ADJUSTMENT SENSITIVITY Pressure Pressure Change Turn bar Adjustment Maximum ft Ibs 8 0 2 7 Flow gpm 3 4 4 6 4 6 Change Turn Ipm 12 9 17 4 17 4 Volume Approx Min gpm 1 0 1 0 1 0 Adjustment Flow Adjust Ipm 3 7 3 7 3 7 Maximum ft lbs 5 5 3 5 3 5 Torque m kg 0 76 0 48 0 48 Form No 265664 Rev 11 08 PVR6 PARTS LIST ITEM PART QTY ITEM PART QTY NO CODE NO DESCRIPTION REQ NO CODE NO DESCRIPTION REQ 1 550177 Pump Body 1 13 307257 Teflon Seal Ring 1 1 4B 550660 Pump Body 1 15 Buna N 124194 O Ring 1 2 550541 Cover 1 15 Viton 147177 O Ring 1 2 4B 550658 Cover 1 17 Buna N 144929 O Ring 1 2
7. 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 startup 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 indicates direction of rotation 2 Pump suction line should extend below the lowest point of oil level but not less than two inches 50 8 mm above reservoir bottom 3 The pump and motor shafts must be aligned within 003 inches 0 076 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 a 10 psi 0 7 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
8. low Spring Housing e Thrust Screw Oil Groove Positions Item 21 Bushing Orientation 3 After the bearings are in place check to see that the rotor shaft 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 and thrust plates 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 springs 9 10 and ring shoe 11 pressure ring 6 and rotorshaft 3 7 To assure proper vane assembly place the vanes 7 with the beveled edge out against the pressure ring 8 Assemble the square seal rings into the cavity in the back of the thrust plate The soft rubber seal ring 15 should be assembled first and the hard seat ring 13 should be assembled on top of them Stretch the larger soft seal ring slightly so it clings to the ID at the cavity Apply clean oil or STP to the back of the thrust plate before it is placed in the locating pins in the body to help hold the parts together while they are assembled 9 Before fitting the cover into the housing check to as
9. me Plate 1 8B3L 8B5L 67 250597 Self Tapping Screw 4 8 10B3L 10B5L 166620 Spring Seat 1 80 002586 Dowel Pin 2 9 4B20 165223 Governor Spring 1 81 1221 21 350663 Spline Coupling 1 9 6B06 149917 Governor Spring 1 85 1221 21 147655 Flange Cover Shipping 1 9 8B06 251193 Governor Spring 1 86 Viton 112222 O Ring 1 9 6B15 8B15 165225 Governor Spring 1 86 1221 21 111298 O Ring 1 9 6B20 8B20 165226 Governor Spring 1 92 256708 SAE O Ring Plug 1 9 6B31 8B3L 257653 Governor Spring 1 93 166288 Caplug C D 1 9 10B3L 109792 Governor Spring 1 94 160259 Caplug In 1 9 6B5L 8B5L 255809 Governor Spring 1 95 137020 Caplug Out 1 9 10B5L 113079 Governor Spring 1 96 1221 21 130437 Caplug Flange 2 10 6B06 8B06 165221 Follower Spring 1 97 12 21 1221 253841 Spline Warning Tag 1 10 10B10 165220 Follower Spring 1 98 143391 Grease A R 10 6B15 8B15 165222 Follower Spring 1 99 132779 LED Plate 250 A R 11 4B 144926 Ring Shoe Assembly 1 Not Shown 11 6B 144913 Ring Shoe Assembly 1 11 8B 162770 Ring Shoe Assembly 1 11 10B 350448 Ring Shoe Assembly 1 11 6B3L 6B5L 112022 Ring Shoe Assembly 1 11 8B3L 8B5L 123174 Ring Shoe Assembly 1 4 Form No 265664 Rev 11 08 PVR6 PARTS DRAWING Code 36 PVR6 KIT LIST WEAR PLATE KITS SEAL KITS ROTATING KITS COMPLETE REBUILD KITS Includes ltems 4 amp 5 Includes Items
10. p adjustment at the volume screw when pressure begins to drop 2 Form No 265664 Rev 11 08 OPERATION PRESSURE AND VOLUME ADJUSTMENTS Pressure Control All pumps are adjusted to reduced pressure before shipment and must be readjusted to the required system pressure after installation and start up 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 increases pressure counterclockwise reduces pressure A pressure gauge located at the pump must be used when making adjustment to insure the pressure settings do not exceed limits specified for the particular pump of maximum system pressure Make all pressure settings with 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 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 a maximum rated volume at the factory unless otherwise specified Stop adjustment of the volume screw when pressure begins to drop See Sales Catalog for complete pump performance spe
11. sult 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 PVR6 pumps or as the coupling manufacturer specifies Installation Continued PIPING AND RESERVOIR The pump should be mounted with a minimum number of elbows or fittings The pump suction should be at least 1 inch 25 4 mm tube pipe for PVR6 pumps For any system and combination of piping except High Water Based Fluids HWBF the vacuum at the pump inlet must not exceed seven 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 inches 50 8 mm from the bottom of the tank All lines returning oil to the tank should discharge at least two 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
12. sure that the bore in the port plate is concentric to the bearing bore in the cover If the bores are not concentric the port place must be relocated 180 on the locating pins 6 Form No 265664 Rev 11 08 PVR6 PUMP REPAIR PROCEDURES Continued 10 Assemble the cover 2 and port plate 4 onto the housing and align the bolt holes Rotate the shaft 3 as the bolts are tightened to assure that the vanes are not cocked 11 Torque the cover bolts 18 to 50 Ibs ft 67 8 Nm The shaft should turn by hand when assembly is complete 12 Lubricate the ID of the shaft seal 24 and press it into the housing to the depth shown below Note the lip to the inside orientation of the seal gt lt 25 6 35 mm Y DAZ 13 Adjust the pressure adjustment screw 30 until it just touches the spring and then give it one more turn clockwise 14 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 15 The pump is now ready to test Refer to front of this manual for start up procedure 0 07 1 78 mm One Vane Thickness Form No 265664 Rev 11 08 CONTINENTAL Continental Hydraulics 5505 West 123rd Street Savage MN 55378 Phone 952 895 6400 Fax 952 895 6444 HYDRAULICS vwww continentalhydraulics com Because Continental Hydraulics is continually improving its products specifi
13. yway 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 retainer 41 and follower spring 10 9 If the shaft seal 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 journal bearing in the housing while the shaft seal is being removed It is recommended that the shaft seal be replaced whenever the pump is disassembled for maintenance The seal cannot be reused once they have been removed 10 The bushings 21 in the pumps are assembled with a press fit If they are to be removed at this time the bushing in the housing should be pressed out from the front The cover bearing should be pulled out using an expanding type puller The bushings 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 bushings 21 in the housing and cover The bushing 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 bushing as shown in the illustration be
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