Continental Hydraulics PVR15-30B-Flanged Series, D Design Series, PVR15-015B15-RF-0-5-F, PVR15-Manifold Series, J Design Series Service Manual
...Page 1
SERVICE MANUAL
PVR15-30B-Flanged Series Pump
Installation, Startup, Operating Instructions, Parts Pages, Repair Procedures
“D” Design Series
This service manual applies to products with Ordering
Codes like the sample below.
PVR15 - 30B15 - RF - _ - 5 - _ _ _ _ _ - D
Basic Pump
Pump Size
& Pressure
Rotation & Mounting
Seal Type
Mechanical Options
Control Options
Design Letter
INSTALLATION
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.
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
consult factory.
CAUTION - Before starting pump, be sure
that any resulting machine function will not
endanger persons or equipment.
PRODUCT IDENTIFICATION
Each pump has an Ordering Code stamped on its
nameplate. See below for the location of the Ordering
Code.
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 3/4 inch (19.05 mm)
for PVR15 pumps, or as the coupling manufacturer
specifies.
PIPING AND RESERVOIR
The pump should be mounted with a minimum
number of elbows or fittings. The pump suction
should be at least 1-1/4 inch (31.75 mm) tube/pipe for
PVR15 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.
Form No. 265283 Rev. 07/08
1
Page 2
Installation (Continued...)
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 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
installation 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.
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.
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. Stop adjustment at
the volume screw when pressure begins to drop.
OPERATION
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 fullsize 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
2
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.
Form No. 265283 Rev. 07/08
Page 3
Operation (Continued...)
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 specifications.
ADJUSTMENT PROCEDURES
To adjust the maximum output volume use the
following steps:
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.
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 30B
Pressure psi 240
Pressure Change/Turn (bar) (16.5)
Adjustment Maximum ft.-lbs. 2.7
Torque (m-kg) (0.37)
Flow gpm 4.6
Change/Turn (lpm) (17.4)
Volume Approx. Min. gpm 1.0
Adjustment Flow Adjust. (lpm) (3.7)
Maximum ft.-lbs 3.5
Torque (m-kg) (0.48)
1. Set the pump at minimum pressure.
2. Hand tighten the volume screw until it touches
pressure ring. NOTE: The pump should be at full flow
for this step.
PVR15-30B KIT LIST (Refer to Drawing and Parts List)
WEAR PLATE KITS
Includes Items: 4 & 5
Model Kit Number
30B 252933
SEAL KITS
Includes Items: 13,14,15,16,17,24,25,85,86,99
Model Kit Number
All Buna-N 250008
All Viton 250009
VANE KITS
Includes Items: 7
Model Kit Number
30B 252932
ROTATING KITS
Includes Items: 3, 6 & 21
Model Code Kit Number
30B Consult Factory
30B 12 252935
30B 21 Consult Factory
30B 22 Consult Factory
COMPLETE REBUILD KITS
Includes Items: All Kits Listed Here Plus Items 11 & 22
Model Code Kit Number
30B 252899
30B 12 252938
30B 21 254999
30B 22 255002
Form No. 265283 Rev. 07/08
3
Page 4
PVR15-30B PARTS LIST
ITEM
N0. NO. REQ.
1 550360 Pump Body 1
2 550629 Cover 1
2 18, 24, 25 550630 Cover 1
2 2118, 2218 550631 Cover 1
2 21, 22, 31 550632 Cover 1
2 24**, 25** 550629 Cover 1
3 550109 Rotorshaft 1
3 12 550148 Rotorshaft 1
3 21 550331 Rotorshaft 1
3 22, 31 550332 Rotorshaft 1
4 450169 Port Plate 1
5 450127 Thrust Plate 1
6 350128 Pressure Ring 1
7 252932 Vane Kit (Set of 26) 1
8 306197 Spring Seat 1
9 112927 Governor Spring 1
10 129915 Follower Spring 1
11 251214 Ring Shoe Assembly 1
12 130041 Pin 1
13 124389 Teflon Seal Ring 1
14 Buna-N 124574 O-Ring 1
14 Viton 127746 O-Ring 1
15 125664 Teflon Seal Ring 1
16 Buna-N 108701 O-Ring 1
16 Viton 113215 O-Ring 1
17 Buna-N 102556 O-Ring 1
17 Viton 117505 O-Ring 1
18 199670 Soc. Hd. Cap Screw 4
19 165219 Thrust Screw 1
20 250368 Thrust Screw Plug 1
21 121566 Bushing 2
22 001396 Key 1
23 105643 Dowel Pin 4
24 113988 Lip Seal (Codes 21/22 -Add 2) 2
24 Viton 121587 Lip Seal (Codes 21/22 -Add 2) 2
25 Buna-N 153111 O-Ring 1
25 Viton 162100 O-Ring 1
30 250240 Pressure Adj. Screw Ass’y. 1
38 36 252152 Handwheel 1
39 36 261323 Spring Pin 1
40 004223 Spring Pin 1
PART
CODE
DESCRIPTION
QTY.
ITEM CODE PART DESCRIPTION QTY.
N0. NO. REQ.
43 122975 Shim (.010) A.R.
44 15 301737 Handwheel 1
45 15 004262 Spring Pin 1
50 Valve Refer to Valve Escutcheon 1
51 17,18**,2500, 350946 Dual Pressure Control Ass’y. 1
25**
53 8, 9 256508 Flow Control Valve 1
55 450196 Volume Adj. Screw Ass’y. 1
56 2400, 24**, 350951 Dual Volume Control Ass’y. 1
2500, 25**
57 8, 9 256509 Union 1
58 18**, 24** 256510 Connector 1
59 25** 256514 Run Tee 1
60 18**,24**,25** 256742 Hose - 18” (Code 25** -Add 1) 1
61 24** 350929 Adapter 1
66 307182S Name Plate 1
67 250597 Self-Tapping Screw 4
69 18**,24**,25** 198225 Soc. Hd. Cap Screw 4
70 18**,24**,25** 012144 Hi-Collar Lockwasher 4
80* 21, 31 147655 Flange Cover (Shipping) 1
80* 22 164598 Flange Cover (Shipping) 1
81 21 350663 Spline Coupling 1
81 22, 31 350664 Spline Coupling 1
82 22 450635 Adapter 1
82 31 450634 Adapter 1
83 22 199682 Button Hd. Cap Screw 2
85 Viton 167682 O-Ring 1
85 21, 22, 31 138362 O-Ring 1
86 Viton 144966 O-Ring 1
86 22, 31 144929 O-Ring 1
87 31 258502 Threaded Rod 1
90* 254832 Flange Protector 1
91* 254831 Flange Protector 1
92 256708 SAE O-Ring Plug 1
93 109376 Caplug (Shipping) 1
94 31 199126 Hex. Nut 2
95 21 008446 Caplug 2
95 22, 31 008345 Caplug 2
97* 12, 21, 22, 31 253841 Warning Tag 1
98* 143391 Grease A.R.
99* 132779 LED Plate #250 A.R.
* Not Shown
4
Form No. 265283 Rev. 07/08
Page 5
PVR15-30B PARTS DRAWING
44
45
30
8
10
43
41
9
11
12
40
39
38
55
13
15
5
6
3
4
17
23
2
23
14
16
22
21
18
95
7
93
20
25
19
67
24
21
1
66
3
81
86
85
82
2
95
83
87
94
See Page 6 for Control Options.
PVR15-30B PARTS DRAWING
Codes 12, 21, 22, 31 Tandem Mounting
Form No. 265283 Rev. 07/08
5
Page 6
PVR15-30B PARTS DRAWING
60
99, 51
69, 70, 50
58
92
60
99, 56
50, 69, 70
61
92
60
99, 56
50, 69, 70
61
92
60
99, 51
57
53
Control Options
Code 17 Dual Pressure Control Without Integral Valve
Code 18** Dual Pressure Control With Integral Valve
Code 2400 Dual Volume Control Without Integral Valve
Code 24** Dual Volume Control With Integral Valve
Code 2500 Dual Pressure/Volume Control Without Integral Valve
Code 25** Dual Pressure/Volume Control With Integral Valve
Code 8 Rate Control Valve for Dual Pressure
Code 9 Rate Control Valve for Dual Volume
6
Form No. 265283 Rev. 07/08
Page 7
PVR15-30B PUMP REPAIR PROCEDURES
Spring Housing
C
L
C
L
Oil Groove Position
Thrust
Screw
Item #21
Journal Bushing Orientation
Pressure Ring
Rotor Shaft
Vane
Item #7
Typical Vane Installation
the pump.
DISASSEMBLY PROCEDURE
NOTE: Disassembling a 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 (18) 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 (23).
5. Remove the vanes (7) with a long nosed pliers or
tweezers. There are two vanes in each slot, 26 vanes
total.
REASSEMBLY PROCEDURE
1. Clean and inspect parts to determine which parts
are worn enough to require replacement.
2. Assemble the new journal 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 below.
3. After the bushings are in place, check to see that
the rotorshaft will fit into the bushings and provide a
smooth turning fit. If the shaft turns hard, the
bushings should be removed and the bore checked
closely for nicks or burrs before pressing in the new
bushings.
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 retainer (41) 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 journal
bushing 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 journal bearings (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 bushing 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
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 spring 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 four seal rings into the cavity in the
back of the thrust plate. The soft rubber o-rings (14,
16) should be assembled first and the hard square
seal rings (13, 15) should be assembled on top of
them. Stretch the larger soft o-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
Form No. 265283 Rev. 07/08
7
Page 8
PVR15-30B PUMP REPAIR PROCEDURES
.374 (9.50 mm)
.100 (2.54 mm)
(Continued...)
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
assure 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.
10. Assemble the cover (2) and port plate (4) onto the
housing and align the bolt holes. Rotate the shaft as
the bolts are tightened to assure that the vanes are
not cocked.
11. Torque the cover bolts (18) to 100 lbs-ft. (135.6
Nm). The shaft should turn by hand when assembly
is complete.
12. Lubricate the ID of the lip seals (24) and press
them into the housing to the depth shown below.
Note the "lip to the inside" orientation of the seals.
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.
Because Continental Hydraulics is continually improving its’ products, specifications and appearance
Form No. 265283 Rev. 07/08 © 2008, Continental Hydraulics. Printed in U.S.A
Continental Hydraulics
5505 West 123rd St.
Savage, MN 55378
Phone: (952) 895-6400 Fax: (952) 895-6444
www.continentalhydraulics.com
are subject to change without notice.
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