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PVG 32 Load Independent Proportional Valve Service Manual

1. Unc A e Upc B PVEO PVEO R U Uu Upc A PVEO DI LED E Upc A A Pinno g DI B Upc B qiBl5 q Mlbt py Hm 2 Dr DI A Ossi OF O uw Qp Ga U pc2 Grey connector N 7 Black connector PVPC plug for external pilot control e P107812E Description Pilot oil supply from another pump Location On the end of the PVP Function Provides a hydraulic pilot supply to the valve stack Failure mode Cause Corrective action Main spool moves slow or not at all in all sections External hydraulic pilot pressure is too low Check external hydraulic pressure from pilot pump and or restrictions 11039167 Rev BA May 2014 41 Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting PVMR Friction Module PVPC plug for external pilot T P Tee into pressure port to measure pressure le 9 fin L PVPC with check valve P107 734E Description Mechanical friction hold Location Mounted on main spool in the PVB Function Infinite mechanical positioning of the main spool Failure mo
2. Failure mode Cause Corrective action Will not build pressure in A or B Contamination preventing shuttle ball from Replace complete PVB module work port building load sense relief pressure LSA B shuttle Shuttle ball P107 821 Main spool Description Main directional control Location PVB valve section module Function Controls oil flow from pump to work ports A or B Failure mode Cause Corrective action Section will not build pressure in one Load sense passages in spool are blocked Flush out load sense passages in the spool Spool will need to be spool direction removed to clean Main valve spool stuck in valve body Refer to Pressure reducing valve Replace PVM and PVE Be sure that pilot valve is assembled if being used with electrical correctly actuator Mechanical actuator main valve Hard particle binding spool in bore Look down into the A and B work ports to see if the particle can spool stuck in valve body be removed while the spool is in the valve body Replace valve section NOTE Valve body and spool will need to be replaced per valve specifications Main spool stuck in valve body Tie rod over torqued Replace tie rod kit which includes section seals and torque to 28 Nm 248 Ibf in Valve stack mounting surface is not flat Ensure the mounting surface is flat causing a bind on the valve stack Flatness in millimeters T 0 35 mm X number of
3. Disassemble and clean Closed center System increase stand by to 20 Bar 290 PSI Open center Check gear per pump manufacturers procedure Check system for other components before valve inlet that may provide a path tank High tank port pressure Tank pressure should not exceed 40 Bar 580 PSI For PVPs without TO option Check for restrictions in return system and remove Oil viscosity 460 mm S 2128 SUS too high cold oil or incorrect viscosity oil Warm up system or replace oil with correct viscosity Serviceability All internal components can be removed from the cavity cleaned inspected and reassembled back into the valve 1 Usea 6 mm internal hex wrench to remove the plug and then remove all the other internal components in the cavity 2 Clean all components with clean solvent 3 Replace any damaged components Lubricate with clean hydraulic oil 4 Correctly reassemble the components back into the cavity and torque the plug to 25 Nm 221 Ibf in use an M5 screw to install spool Pressure reducing pilot valve Plug V 6mm e 25 Nm 7 220 Ibfein 11039167 Rev BA May 2014 21 Donfsi Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting Pressure gauge connection Description Port to install a pressure gauge to check pressure relief valve setting to valve specification Location On in
4. Pump applies pressure to the right hand side of the pressure adjustment spool 6 The pressure relief valve 1 opens if the load pressure exceeds the set value diverting pump flow back to tank In a pressure compensated basic module the compensator 14 maintains a constant Pressure drop across the main spool both when the load changes and when a module with a higher load pressure is actuated With a non pressure compensated basic module incorporating a load drop check valve 18 in channel P the check valve prevents return oil flow The basic module can have the load drop check valve in channel P for functions with over center valves The shock valves PVLP 13 with fixed setting and the suction valves PVLA 17 on ports A and B are used for the protection of the individual working function against overload and or cavitation An adjustable Load Sensing LS pressure limiting valve 12 can be built into the A and B ports of pressure compensated basic modules to limit the pressure from the individual working functions The LS pressure limiting valves save energy compared to the shock valves PVLP With PVLP all the oil flow to the working function flows across the combined shock and suction valves to tank if the pressure exceeds the fixed setting With LS pressure limiting valves an oil flow of about 2 l min 0 5 US gal min flows across the LS pressure limiting valve to tank if the pressure exceeds the valve setting PVG 32 group with cl
5. Replace complete module 32 11039167 Rev BA May 2014 Denpi Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting Serviceability Load drop check valve is not serviceable If you suspect valve malfunction replace complete module Load drop check valve 4 ge I EZ UI j V Load drop check valve P107747E o Cip O Load drop check valve P107 748E Maximum oil flow adjustment screws for ports A and B Description Optional mechanical flow limiter Location PVM manual control handle Function Determines the stroke of the main spool in the PVB Failure mode Cause Corrective action Cylinder motor functions too slow Mechanical stop screws out of adjustment per Use a 8mm open end wrench to loosen the jam nut and then 3mm or too fast valve spec internal hex wrench to adjust the mechanical adjusting screw CCW to increase speed After adjusting hold the adjusting screw and torque the jam nut to 8 Nm 70 Ibf in maximum Leaking past adjusting screws Check torque on seal nut 8 Nm 71 Ibf in Retorque or replace seal nuts e Caution When adjusting main spool flow ensure that electrical or hydraulic actuators are not active at the time if so equipped 11039167 Rev BA May 2014 33 Service Manual PVG 32 Proportional Valve Group
6. Rev BA May 2014 Service Manual PVG 32 Proportional Valve Group System Troubleshooting Cause Check Corrective action Main spool position feedback transducer signal incorrect Check feedback pin for damage Replace PVE Contamination in hydraulic oil Take oil sample Flush complete system Fill reservoir with clean filtered fluid per OEM specification Air in hydraulic pilot lines Check for air trapped in signal lines from the controller to the valve section module Bleed air from the hose connection at the valve section Hydraulic remote actuator faulty Check signal pressure from the remote hydraulic controller Repair or replace cylinder motor Low hydraulic oil supply Hydraulic oil supply Check fluid level in reservoir Fill reservoir with clean filtered fluid per OEM specification Cause Check Corrective action Pump not running Check prime mover for operation Check condition of drive coupling Repair or replace prime mover Repair or replace drive coupling Insufficient oil in reservoir Check fluid level in reservoir Fill with clean filtered oil Leaking or burst supply hose Inspect lines to valve stack Repair or replace damaged hose Relief valve malfunction Isolating valves are closed Check for contamination and operation of relief valve Check that all isolating valves are open and clear Repair or replace reli
7. Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting PVPVM module PVS plugs PVSI NN SN P107 707E For specifications and operating parameters on PVG 32 valves refer to PVG 32 Technical Information Manual 520L0344 Description Mid inlet module only for closed center systems Location Mounted between multiple PVB s in a valve stack Function Provides pressure and tank connections to the valve stack allowing increased flow Failure mode Cause Corrective action Leaking externally between PVPVM and PVB Uneven mounting surface and mounting screw torque Ensure the valve stack is mounted on a even surface and torque down correctly Tie rods torqued too tight Replace tie rod kit which include section seals and torque to 28 Nm 248 Ibf in Flow exceeding 61 gpm Lower flow to 61 gpm and replace the tie rod kit and seals per valve spec Valve stack can not build pressure Option PVLP shock valve not seating correctly in cavity caused by valve not being installed correctly or it has failed Install components correctly or replaced damaged components Flatness in millimeters T 0 35 mm X number of PVB modules 1 36 11039167 Rev BA May 2014 Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting PVPVM module Do not try to adjust a or disas
8. 300 4000 250 3000 200 20001 190 100 1000 50 PVBS 0 0 gt o N w A a o N 3 3 157 156 10 PVPX Electrical LS unloading valve PVPX is a solenoid LS unloading valve PVPX is fitted into the pump side module enabling a connection to be made between the LS and the tank lines Thus the LS signal can be relieved to tank by means of an electric signal For a PVP pump side module in open center version the relief to tank of the LS signal means that the pressure in the system is reduced to the sum of the tank port pressure plus the neutral flow pressure for the pump side module For a PVP pump side module in closed center version relief to tank of the LS signal occurs when the pressure is reduced by the sum of the tank port pressure for the pump side module plus the stand by pressure of the pump 157 195 11 e Caution Protect yourself from injury Use proper safety equipment including safety glasses at all times 11039167 Rev BA May 2014 13 Service Manual PVG 32 Proportional Valve Group System Troubleshooting Overview A Warning This troubleshooting guide for the PVG valve assemblies does not cover valves that have been altered from original valve build specifications This section provides general steps to follow if undesirable system conditions are observed Follow the steps listed until the problem is solved Some of the items will be system specific Always obser
9. M PVEH F PVEH F INA ANA L H U ERN Float rms SETA ho A oc Error 5 l 2 t yu Error 1 29 95 Us 40S Pi DC 19 ed Grey connector Us Us Ta y con SSS oY M P107 809E PVEO On Off electrical actuator Description Proportional electrical actuator Location On the end of the main spool of the PVB Function Convert an electrical command to move the main spool to a set position Failure mode Cause Corrective action Does not work in either direction No control voltage from the electrical controller Check voltage from the electrical controller Resistance check measures between pin 2 and ground 17 OHMs for 12 volt systems 63 OHMs for 24 volt systems Command pin wire in mating connector is broken Repair broken wire Connector corroded Replace PVE and mating connector This condition is caused by water ingression or ground connection 24 volt electrical actuator used on a 12 volt system Replace with the correct electrical actuator for a 24 volt system No power from the battery Check power to electrical actuator Power pin wire in mating connector is broken Repair broken wire Ground connection must be hard wired straight from the battery or from the electrical controller Repair ground connection Works in one direction Assuming that the manual control lever and the main spool moves freely both directions No control voltage from t
10. behind disk eio PVB Ball should move freely behind disk P107 804 Description Optional adjustable pilot relief valve Location PVB spool body section module Function Controls the maximum working pressure delivered to each work port There is one LS pressure limiting valve for each work port Failure mode Cause Corrective action Section will not build pressure in one spool direction Contamination While under pressure back out to minimum pressure and allow oil to leak by for approx 5 seconds and then readjust to correct pressure Ensure system is clean Replace PVB External leaking Low cartridge torque Torque to 20 Nm 177 Ibf in maximum Replace complete assembly Pressure adjustment backs off Adjust pressure to valve specifications If adjustment doesn t hold replace valve Serviceability Adjustable and non serviceable If adjustment does not solve the problem replace complete cartridge Valve removal tool P N 155L6485 Torque to 20 Nm 177 Ibf in LS A B shuttle Description The shuttle valve isolates the LS A and LS B load sense signal Location Option PVB module with only load sense relief Function Ensure that each pressure limiter valve can create separate pressures for A and B LS signal 28 11039167 Rev BA May 2014 Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting
11. connection port A 6 Pressure adjustment spool 16 LS connection port B 7 Plug closed centre 17 Suction valve PVLA 8 LS connection 18 Load drop check valve 9 LS signal 19 Pilot oil supply for PVE 10 Shuttle valve 20 Max oil flow adjustment screws for ports A and B 11039167 Rev BA May 2014 Service Manual PVG 32 Proportional Valve Group Operation PVPC plug for external pilot oil supply PVPC with check valve for open center PVP PVPC with check valve is used in systems where it is necessary to operate the PVG 32 valve by means of the electrical remote control without pump flow When the external solenoid valve is opened oil from the pressure side of the cylinder is fed via the PVPC through the pressure reducing valve to act as the pilot supply for the electrical actuators This means that a load can be lowered by means of the remote control lever without starting the pump The built in check valve prevents the oil from flowing via the pressure adjustment spool to tank With the pump functioning normally the external solenoid valve is closed to ensure that the load is not lowered due to the pilot supply oil flow requirement of approximately 1 l min 0 26 US gal min With closed center PVP the external pilot oil supply can be connected to the pressure gauge connection without the use of a PVPC plug T P Oil Flow Direction
12. 1000 Jin Hai Rd Jin Qiao Pudong New District Shanghai China 201206 Phone 86 21 3418 5200 Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 11039167 Rev BA May 2014 www danfoss com Danfoss A S 2014
13. Do not exceed maximum torque Check movement of manual lever when electrical controller is operated If manual lever does not move in one direction check electrical signal from controller and wiring at the PVE module Check movement of manual lever when hydraulic controller is operated If manual lever does not move in both directions check hydraulic pressure at the PVG module Air in system Entrained air generates heat under pressure Look for foam or bubbles in reservoir Check for leaks on inlet side of charge pump Internal leakage Excessive internal leakage may overheat the system Install loop flushing defeat option and monitor case flow If case flow is excessive motor may require major repair Contact Danfoss Service Shock valves Swap and see if problem follows Replace valves Solenoid actuation If power is OK from controller Repair wiring to PVE module Main spool travel restricted Stop on manual controller turned in too far Back out manual stop on manual controller Remote electrical controller Insufficient signal from electrical controller Repair or replace electrical controller PVEO connections Incorrect PVE PVEO connections Connect correct way Remote hydraulic controller PVRH Insufficient pilot oil pressure from remote hydraulic controller Pressure needs to be 25 Bar 360 psi Repair or replace remote hydraulic controller Main valve
14. EM electrical actuators The interaction between the small dead band of the spools and the hysteresis of the PVEM actuator of 20 involves a risk of building up a LS pressure in neutral position PVBS main spools for pressure control In a few systems load sensing pump pressure may result in unstable adjustment of the oil flow and a tendency towards system hunting This may be the case with working functions that have a large moment of inertia or over center valves In such systems main spools for pressure control can be advantageous The spools are designed in such a way that the pump pressure is controlled by the spool travel The main spool must be displaced until the pump pressure just exceeds the load pressure before the working function is applied If the main spool is held in this position the pump pressure will remain constant even if the load pressure changes giving a stable system The use of pressure control spools however also means that e the oil flow is load dependent the dead band is load dependent the pump pressure can exceed the load pressure by more than is usual 12 11039167 Rev BA May 2014 Zonen Service Manual PVG 32 Proportional Valve Group Operation Due to these factors use pressure control spools only when you know for certain that problems with stability will arise or already have arisen Use LSa g when pressure stability is an issue Fb n psi bar
15. LS Oo aw QC o ww 157 114 11 PVPC without check valve for open center PVP PVPC without check valve is used in systems where it is necessary to supply the PVG 32 valve with oil from a manually operated emergency pump without directing oil flow to the pilot oil supply oil consumption about 1 l min 0 25 US gal min When the main pump is working normally the oil is directed through the PVPC plug through the pressure reduction valve to the electrical actuators When the main pump flow fails the external shuttle valve ensures that the oil flow from the manually operated emergency pump is used to pilot open the over center valve and lower the load The load can only be lowered using the mechanical operating lever of the PVG 32 valve With closed center PVP the external pilot oil supply can be connected to the pressure gauge connection without the use of a PVPC plug P LI Oil Flow Direction i 157 114 11 10 11039167 Rev BA May 2014 Zones Service Manual PVG 32 Proportional Valve Group Operation For specifications on PVG 32 valves refer to PVG 32 Technical Information Manual 520L0344 Friction detent PVMR Friction detent The friction detent PVMR allows the directional spool to be held in any position resulting in infinitely variable pressure compensated flow The spool position will be held indefinitely without the
16. MAKING MODERN LIVING POSSIBLE Service Manual PVG 32 powersolutions danfoss com Service Manual PVG 32 Proportional Valve Group Revision history Table of revisions Date Changed Rev May 2014 Converted to Danfoss layout DITA CMS BA Feb 2006 Aug 2013 Various changes AB BA 11039167 Rev BA May 2014 Service Manual PVG 32 Proportional Valve Group Contents Introduction Operation System Troubleshooting eI m M O 5 General instructions 5 Remove the unit 5 Keep it clean 5 Replace all O rings and gaskets 5 Secure the unit 5 Safety PME CAUTIONS REID ssbassudusentesteccledes 6 Unintended machine MOVEMENL ssssssssccssssecsessssesesssssecssssssesssssssecsessssecsssssssecsessnsecssssssseesessssecsessnnseesecsnsecessnnneessessssees 6 Flammable cleaning SOIVENtS ccsssccsssssccsssccssssessssssecsseeessuseccuseessssececsuceessueesssssecsssscsesuseccsuesssuesssuseesssecsesueeessaeessueesssnees 6 Fluid under de IS V RR 6 Personal Safety cscssscissscssssscecsasacsdasggsaseecenivaccegacconestestoasasnss avusyncstscsqnasavenaissatedoagonsersenednctaugacesvendustauscuqysscnsssnstasslanussenaasesioasassovecenee 6 Hazardous material savsscssscssessssssscsavsessinasecssvsssvesebtuasestensilessodenasesseotiaussedonnuatseessiatedoaassssetbtsncyddnaguaiteposissdednaniestatsaie
17. PVB modules 1 Serviceability Main spool is serviceable depending on failure mode 1 Remove manual actuator using a 5 mm internal hex wrench to remove the 4 mounting screws CAREFULLY place the main spool in to an appropriate fixture or vice with card board rubber hose or heavy shop towels on the jaws and tighten just enough to keep the spool from turning in the vice DO NOT over tighten the main spool in the vice as it will be distorted and or scratched on sealing lands and the spool will need to be replaced 2 Remove the tension rod end using a 13 mm open end wrench 3 Remove the plug at the other end using an 11 mm or if it has a detent option use a 12 mm open end wrench 11039167 Rev BA May 2014 29 Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting 4 Flush out openings into the main spool cavity at each end 5 Install plug with a 11 mm or 12 mm open end wrench Torque to 8 Nm 70 Ibf in 6 Install centering spring and tension rod using a 13 mm open end wrench and torque to 8 Nm 70 Ibf in 7 Carefully reinstall the main valve spool into the valve housing Do not force the main spool back into the housing as you will damage the sealing lands in the valve housing The spool should move freely in the main spool bore when fully installed 8 Install a manual actuator Reassemble in reverse order and torque the 4 mounting screws to 8 Nm 70 Ibf in If section does not buil
18. PVE Incorrect PVE connections Check that the proportional remote electrical controller has not been connected to an ON OFF PVEO solenoid Hydraulic remote pilot control pressure Connect wires correctly Cause Check Corrective action Insufficient pilot pressure B port on remote Check pilot oil pressure 5 15 bar 72 220 psi delta between A and PVG32 5 15 Bar 72 217 PSI Insufficient pilot oil supply Check pilot oil flow rate is adequate Pilot flow should be 1 0 L min 0 264 GPM per section Check pilot lines for blockage Remove blockage Air in pilot line Check for trapped air in pilot lines Bleed air from pilot lines at PVH Pilot lines incorrectly sized Check pressure drop Check and reduce length or pilot lines Increase diameter of pilot lines Use steel tube for long pilot line runs Hydraulic remote pilot operator faulty Check operation of hydraulic remote pilot controller Repair or replace Check supply pressure to hydraulic remote controller minimum 25 bar 360 psi Repair or replace Check and inspect movement of pressure control valve in hydraulic controller Repair per manufacturers procedure or replace Check operation of remote hydraulic controller Clean and or repair as necessary 11039167 Rev BA May 2014 Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshoo
19. PVG 32 Component Troubleshooting Adjusting screws for ports A and B For standard mount top adjusting screw is B and bottom adjusting screw is A P107 816E PVM module Description Manual control lever Location Mounted on either end of the PVB main spool Function Manual override capable of limiting the stroke of the main spool and is used to center the spool in neutral Failure mode Cause Corrective action Leaking externally between PVM _ Back pressure is exceeding 40 Bar 580 PSI on Replace PVM module seals and lower tank port pressure and PVB tank line H i connected to tank or restricted or Connect to tank remove restriction and remove blockage ocke 34 11039167 Rev BA May 2014 Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting PVM module O rings Screw x4 5mm e 8 Nm 70 Ibfsin P197 806E PVS module Description End cover Location Mounted on the last PVB of the valve stack Function Serves as blanking cover and drain for LS circuit Failure mode Cause Corrective action Leaking externally between PVS Back pressure is exceeding 40 Bar 580 PSI on Replace PVS module seals and lower tank line pressure and PVB tank line Maximum pressure Aluminum 300 bar 4500 psi Steel 350 bar 5000 psi Reduce system pressure 11039167 Rev BA May 2014 35
20. a denaseatsetonveitie 6 ACEIODVETIS iiiaae aire aA TIARNE TE VELERIP GRAN ORAN RIVE RENTA NNNM INTE UTE ON O R prt red 6 PVG 32 group with open center PVP PVB with flow control SPOOI sssscsssssccssesscesseccssseccssecesssecesssececssecssseseetsnecesnees 8 PVG 32 group with closed center PVP PVB with flow control SPOOI sssscsssssscssteccsssecesseesessccsssecesuecssneeseensecssnees 8 PV 32 sectional drawing eoe ere Reprise aT aE RA EOE o eene Rei te ESPERE 9 PVPC plug for external pilot oil supply 10 PVPC with check valve for open center PVP 10 PVPC without check valve for open center PVP Friction detent esent 51 PVMR Friction detent ise sell PVMF Mechanical float position lOCk ssssssssssscsssesscssseesssessssseccsuseessssesssnscessuecsssueersnseeesaseecsuseessuseessaseessneesesnseersneeesses 11 PVBS main spools for flow control StANAALA ssesscccssecsssessesssecesssceessseccsssccesssesecsseccsnsececusecssnseessasecesnseessneeeesaseeseneeesees 12 PVBS main spools for flow control with linear Characteristics sssssscccssessssssccsseessseseccseesesseeessneeessseessansecesseesseess 12 PVBS main spools for pressure CONTIOL ssssccssssccseecsssscccsseccessecesssesccssecessussecssecessuecessuecessseesssuteessneesssueeecsuecessueesssneessneess 12 PVPX Electrical LS unloading VAalVE essscsssscsssscccssescsnsecessseecssseecsssceccssecessuecessuseessucce
21. ation PVB Valve section Module Function In a pressure compensated basic module the compensator maintains a constant pressure drop across the main spool both when the load changes and when a module with a higher load pressure is actuated Failure mode Cause Corrective action Valve section unstable flow High wear allows leakage Replace complete module LS pressure limiting valve pressure adjustment High wear Replace complete module will not remain static Serviceability Pressure compensator is not serviceable If you suspect valve malfunction replace complete module 11039167 Rev BA May 2014 31 Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting Load drop check valve Pressure compensator valve Pressure compensator spool SE oe Q Qi e QE P107 744E Pressure compensator spool Y on P107 822 zc Description Keeps the load from dropping when transitioning from spool neutral to lifting the load Location PVB valve section module Function Optional drop check to keep the load from dropping Prevents high pressure functions from supplying low pressure functions when both are actuated simultaneously Failure mode Cause Corrective action Load drops excessively when trying to lift load Worn parts Replace complete PVB module Hard particle in seat area does not allow the seat to seal
22. ceable 1 Use a 6 mm internal hex to remove cavity plug from valve wu BF WN Use a 4 mm internal hex to remove closed center plug Use a 2 5 mm internal hex to remove orifice Clean or replace orifice Install orifice Torque to 4 Nm 35 Ibf in Install new seal and install closed center plug Torque to 8 Nm 71 Ibf in 6 Install new O ring and install plug Torque to 35 Nm 130 Ibf in Closed center plug Plug 9 6 mm O ring E Closed center plug Pu 2 4mm Orifice 3 8 Nm 70 Ibf in 9 2 5 mm 4 Nm 35 Ibf in 2 135 Nm 308 Ibf in P107 737E Description Main pump flow unloading spool Location PVP inlet module Function For open center systems it is the main relief and unloading spool For closed center systems it is the main relief spool Failure mode Cause Corrective action In open center systems the valve sections are unstable High wear allows leakage to tank Replace compete module The adjusted pressure will not remain static in a closed center system around spool to tank Low viscosity oil allowing high leakage Remove and clean orifice Reinstall High wear Replace compete module Serviceability Spool is not serviceable Replace complete module 24 11039167 Rev BA May 2014 Service Manual PVG 32 Propor
23. d pressure in one direction wrong spool may have been installed in valve Main spool Screw 5 11mm z 8Nm 70 Ibf in P107 805E Shock and anti cavitation valve PVLP Description Optional work ports non adjustable pressure relief valve Location PVB valve section Module Function Removes any transient pressure spikes generated by the load The shock valves PVLP with fixed setting and the anti cavitation valves PVLA on ports A and B are used for the protection of the individual work function against overload and or cavitation There is one shock valve for each work port Failure mode Cause Corrective action Will not build pressure in A or B Valve may be damaged and not able to seal Replace with correct part number per valve specification port Serviceability This valve may be disassembled and cleaned however internal parts are not available separately If you suspect valve malfunction replace with a new valve and test system operation 30 11039167 Rev BA May 2014 Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting PVLP valve Plug 5 13 mm e 36Nm 310 Ibf in Do not try to adjust or disassemble PVLP P107 743E Pressure compensator Description Optional pressure compensator maintains a constant pressure drop across the main spool Loc
24. de Cause Corrective action Flow changes Excessive flow across the main spool Reduce flow 100 l min or less Vibration Reduce vibration Broken spring Replace broken springs Flow changes or will not stay in detent Check for proper assembly of parts Install parts correctly per specification sheet 42 11039167 Rev BA May 2014 Service Manual PVG 32 Proportional Valve Group PVG 32 Component Troubleshooting PVMR module Fa g Plug Ne 36mm S 15 Nm PB A 133 Ibf in gt Plug x3 5 11mm ES 4Nm Mechanical detent 35 Ibf in Screw x4 O5 mm 8 Nm P107811E 157 204 10 11039167 Rev BA May 2014 43 Products we offer Danfoss Power Solutions is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions that Bent Axis Motors excel in the harsh operating conditions of the mobile off highway market Building on our extensive Closed Circuit Axial Piston Pumps and Motors applications expertise we work closely with our customers to ensure exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles to Dis
25. e transducer Remote electrical controller neutral position switch faulty Disconnect the connection at the PVE It should come back to neutral Repair or replace faulty switch or wiring at remote controller Sticking pressure control valve in remote hydraulic controller Disconnect the hydraulic signal line from valve Repair or replace faulty remote hydraulic controller Sticking main spool in valve section Internal fault in the PVE PVEH PVEM Remove manual electrical and hydraulic actuators from the valve section Remove main spool from valve section and inspected for damage If no damage reinstall the main valve spool Spool should move freely in the valve section bore PVEO check continuity All other PVE check LED Red means Replace the valve module and main spool if any damage is found on the main spool Replace faulty PVE PVEH PVEM PVEO PVEO internal error Contamination in the hydraulic oil Take oil samples to confirm Flush hydraulic system Fill with clean filtered oil Cylinder motor responds slowly to remote electrical or hydraulic controller actuation Cause Check Corrective action Insufficient system pressure Install pressure gauge and record pressure If pressure is low adjust pressure setting to valve specification or pump manufacturers specification Main spool travel limited Check stops on manual lever controller end for proper adjustment R
26. ecsssueesaseceesseeessneceesseessaseecsaneeseaseessaseets 23 cecinit 24 ESI 25 EXISprme m 26 k lul M M 27 LS pressure limiting valve 28 LS A B shuttle 28 Main spool sees 29 Shock and anti cavitation valve PVLP ssssssscssssssccssseessccssseesecssssessccssssesessssnseccessssesessssssecsessssesessnsnsecsessunesesensnsecsessnneeseens 30 Pressure eolpMIe atltelpee m EEAS REESS 31 Load drop check valve 32 Maximum oil flow adjustment screws for ports A and B sssssssssscssseccssseccssseccsssecsssseessuseccsneceesueessuecessueecssuseessueessensensee 33 EMI 34 11039167 Rev BA May 2014 3 Service Manual PVG 32 Proportional Valve Group Contents PVS 1M OCU ERE E nna E E R a Eini 35 PVPVM module 36 PVAS module 37 PVPX ES UMIOAGING ValVEs ccsasscocsiescsassiesancscseasvesaseievasevainseassoagescnsevgnsnsconnsesnnassdsnaacoanusconsaqstansscansnsecsiadzesdseegsadonsenivascusnesebnedestancann 38 PVEH PVES PVEA electrical ACtUatOrs i scscssssssscssssssssssssssessssssssessssssssessesssssessessssssssssssssesssssssssssssssssssssssssssssssssssessesssseese 38 Troubleshooting Considerations 5438 PVEO On Off electrical actuato
27. ection Remove main spool from valve is found on the main spool section and inspected for damage If no damage reinstall the main valve spool and it should move freely in the valve section bore Check movement of manual lever when electrical If manual lever does not move check electrical voltage controller is operated signal from controller wiring at the PVE module Check movement of manual lever when hydraulic If manual lever does not move check hydraulic controller controller is operated pressure at the PVG valve module 25 Bar 360 PSI If none of the above check pump per manufacturers Repair or replace pump per manufacturers recommended procedure recommended procedure Internal filters blocked Check for blockage in internal filters Remove blockage 11039167 Rev BA May 2014 15 Service Manual PVG 32 Proportional Valve Group System Troubleshooting Cylinder motor responds in one direction only Cause Check Corrective action Verify if fault is mechanical electrical or hydraulic Operate manual lever in both directions to confirm if mechanical or electrical or hydraulic If moving the manual lever operates the cylinder motor in both directions check electrical or hydraulic If operating the manual lever strokes the cylinder motor in one direction only check manual stop screw adjustment Back out manual stop on manual controller and torque the jam not to 8 Nm 70 Ibf in
28. ef valve Faulty pump control Low standby pressure in PVP open center pump Check pump compensator for correct operation and setting per pump manufacturers Check idle standby pressure 10 Bar 145 PSI Repair or replace pump compensator per pump manufacturers recommendations Replace Check condition of compensator spool spring Replace module due to worn components Low standby pressure in pump control variable pump Check pump LS control for operation and setting Stand by pressure should be 15 bar 220 psi minimum Repair or replace LS control per pump manufacturers procedures PVP pressure relief valve faulty Check pressure relief valve spool and spring for freedom of operation Replace PVP orifices blocked Check PVP orifices for blockage Remove blockage Internal filters blocked Supply lines blocked Check for blockage in internal filters Inspect supply lines for blockages Remove blockage Remove blockage Internal hydraulic pilot pressure insufficient Blocked LS galleries Inspect pilot oil pressure reducing valve for proper operation Check LS galleries for blockage Repair or replace Clean blockage from LS galleries Shuttle valves faulty Check LS system shuttle valves for wear and damage Replace as needed Check for contamination per specification HPP 030 Refer to Design Guideline for Hydraulic Fluid Cleanliness Technical Informatio
29. efer to Component troubleshooting section Adjust the manual lever stops and torque the jam nuts to 8 Nm 70 Ibf in Do not exceed maximum torque Incorrect signal voltage from electrical controller Check the signal voltage from the controller with a volt meter If signal voltage is incorrect repair or replace electrical controller Incorrect hydraulic pressure signal from remote hydraulic controller Check pressure from the remote hydraulic controller 25 Bar 360 PSI If pressure is too low repair or replace remote hydraulic controller per manufacturers instructions Insufficient pilot oil all sections Check pilot for contamination and correctly assembled parts 10 15 bar 145 218 psi Electric 25 bar 360 psi Hydraulic Replace inlet module NOTE Check with S D TST Insufficient L5 pump stand by pressure Check pilot PSI 10 15 bar 145 218 psi Electric 25 bar 360 psi Hydraulic Adjust or replace pump Flow is not load independent PVLP check for cracks Check LS pressure vs load pressure Replace valve Erratic cylinder motor response to electrical or hydraulic controller operation Cause Check Corrective action Electrical actuator faulty Check signal from controller to PVE Repair or replace PVE Main spool centering spring damaged Check tension rod for correct torque or damage Torque to 8 Nm 70 Ibf in or replace 11039167
30. eplace open center plug 4 Install open center plug 5 Torque plug to 4 Nm 35 Ibf in 6 Install new seal washer and install cavity plug Torque to 35 Nm 130 Ibf in Open center plug Plug 9 6 mm e 35 Nm 308 Ibf in Seal dieere 7 Dee Open _ center plug 9 3mm 4 Nm 35 Ibf in P107 736E Closed center plug and orifice Description Plug that is installed in the inlet cover for a system with a variable displaceme