PVG 32 Proportional Valves Service Manual
Contents
1. Error 1 No con S nection U P107 809E 43 SAUER DANFOSS PVEO ON OFF ELECTRICAL ACTUATOR PVG 32 Service Manual PVG 32 Component Troubleshooting SG Genuine Parts 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 the el2. S SAUER PVG 32 DANFOSS Service Manual PVG 32 Component Troubleshooting PRESSURE REDUCING PILOT VALVE CONTINUED 5 Genuine Parts Failure mode Cause Corrective action Main spools are slow driven by PVE 13 Bar 190 PSI pilot system Contamination Disassemble and clean Pump pressure too low below 9 Bar 130 PSI Closed center System increase stand by to 13 Bar 190 PSI Open center Check gear per pump manufacture procedure Check system for other components before valve inlet that may provide a path tank High tank port pressure Do not exceed 40 Bar 580 PSI tank pressure For PVPs without TO option Clear restrictions in return system Oil viscosity 460 mm S 2128 SUS too high cold oil or incorrect viscosity oil Warm up system or replace oil with correct viscosity Main spools will not move mechanically or electrical For TO option only not being connected to tank or restricted to tank Connect TO PVP port option to tank or remove restriction Internal pressure reducing valve parts misassembled Reassemble the internal pressure reducing valve parts correctly PVHC 25 bar 360 psi pilot system main spools are slow Contamination Disassemble and clean Pump pressure too low below 20 Bar 290 PSI Closed center System increase stand by to 20 Bar 290 PSI Open center Check gear per pump manufacturers procedure Check system for other comp
3. SAUER PVG 32 S DANFOSS Service Manual G PVG 32 Component Troubleshooting ba PRESSURE Description Optional pressure compensator maintains a constant pressure drop across COMPENSATOR the main spool Location 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 High wear Replace complete module adjustment will not remain static Serviceability Pressure compensator is not serviceable If you suspect valve malfunction replace complete module Pressure compensator valve P107 744E Pressure compensator spool Pressure compensator spool WV es P107 822 11039167 Rev AE November 2012 35 SAUER PVG 32 S DANFOSS Service Manual 2 PVG 32 Component Troubleshooting Genuine Parts LOAD DROP CHECK Description Keeps the load from dropping when transitioning from spool neutral to VALVE 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 Co
4. SAUER DANFOSS PVG 32 Proportional Valves Service Manual SAUER PVG 32 S DANFOSS Service Manual G Revisions Genuine Parts HISTORY OF REVISIONS Table of Revisions Date Page Changed Rev November 2012 41 Revised torque on assembly nuts AE December 2011 41 Revised torque on assembly nuts AD October 2010 last new back page AC March 2010 last Fix Osaka address AB August 2008 First edition AA 2012 Sauer Danfoss All rights reserved Sauer Danfoss accepts no responsibility for possible errors in catalogs brochures and other printed material Sauer Danfoss reserves the right to alter its products without prior notice This also applies to products already ordered provided that such alterations aren t in conflict with agreed specifications All trademarks in this material are properties of their respective owners Sauer Danfoss and the Sauer Danfoss logotype are trademarks of the Sauer Danfoss Group 2 11039167 Rev AE November 2012 SAUER DANFOSS INTRODUCTION OPERATION SYSTEM TROUBLESHOOTING PVG 32 Service Manual 6 Contents Genuine Parts Overview sses General instructions Safety PFECAULIONS sms Unintended machine movement ner 6 Flammable cleaning solvents nn 6 Fl id under pressures Ni ia aR 6 Personal safety 0 Hazardous material 6 PU 0 LE LLC ycboecasocnsstaasnvccogsondsvedsa
5. 308 Ibfein Failure mode Cause Corrective action Leaking Bad seal Replace with new seal same type as original seal Pressure gauge port Of Pressure gauge port P107 735E When valve is equipped with the PVPC option use a running tee to measure pressure Torque tee to hose adaptor torque specification PVPC with check valve Tee into pressure port to measure pressure T P Wo PVPC with check valve LS P107 734E 24 11039167 Rev AE gt November 2012 SAUER DANFOSS OPEN CENTER PLUG PVG 32 Service Manual 6 PVG 32 Component Troubleshooting Genuine fai Description Plug that is installed in the inlet cover for a system with a fixed displacement pump Location In the PVP module Inlet cover Function Connection for the load sense signal to shift the unloading spool to build main system pressure and provides a connection to the main system relief valve Failure mode Cause Corrective action Valve operates at system relief setting at all times Open center plug is not seated properly Reinstall plug and torque to 4 Nm 35 lbf in using a 3 mm internal hex wrench Serviceability Open center plug is serviceable 1 Use a 6 mm internal hex to remove cavity plug from valve 2 Use a3 mm internal hex to remove open center plug 3 Clean or replace open center plug 4 Install open center plug 5 Torque plug to 4 Nm 35 Ibfein 6 Install new s
6. Repair or replace pump compensator per pump manufacturers recommendations Low standby pressure in PVP open center pump Check idle standby pressure 10 Bar 145 PSI 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 Check for blockage in internal filters Remove blockage Supply lines blocked Inspect supply lines for blockages Remove blockage Internal hydraulic pilot pressure insufficient Inspect pilot oil pressure reducing valve for proper operation Repair or replace Blocked LS galleries Check LS galleries for blockage 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 Information Manual 520L0467 If fluid is out of spec flush hydraulic system and fill with clean filtered oil
7. the oil is directed through Ls 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 Oil Flow Direction 157 193 11 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 For specifications on PVG 32 valves refer to PVG 32 Technical Information Manual 520L0344 With closed center PVP the external pilot oil supply can be connected to the pressure gauge connection without the use of a PVPC plug 11039167 Rev AE November 2012 PVG 32 S TO Service Manual S Operation Genuine Parts 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 necessity of holding the mechanical lever PVMR should only be used together with PVB basic modules with pressure compensator 157 204 10 PVMF Mechanical float position lock This allows the float spool to be held in the float position after release of the mechanical handle PVMF PVMF P gt A gt F P gt B gt F Standard assembly Standard
8. 20 11039167 Rev AE November 2012 S SAUER PVG 32 DANFOSS Service Manual ELECTRICAL SUPPLY System Troubleshooting 5 Genuine Parts Cause Check Corrective action No electrical power Check electrical circuit Repair as needed Verify emergency stop switch is in the proper operating position Reset Neutral position switch faulty Check operation of neutral position switch in remote controller if connected in circuit PVRE PVRES PVREL Replace switch Incorrect signal voltage Solenoid valve faulty PVHC Check voltage levels at solenoid plug Proportional operation Refer to page 43 Udc Supply voltage 100 Us Supply signal voltage 25 50 75 Ground Live or ground connection On Off Operation Udc Supply voltage if selected Us Supply voltage if selected Ground Live or ground connection Check coil resistance Check data for resistance Insufficient pilot supply Check pilot pressure 10 15 bar 145 218 psi PVHC 25 bar 360 psi Replace Main spool position feedback transducer signal incorrect Incorrect PVE connections Test oil for contamination and or water content Check that the proportional remote electrical controller has not been connected to an ON OFF PVEO solenoid If oil contamination is too high flush hydraulic system or replace oil if necessary If problem persists change PVE Connect wires corr
9. Tee into pressure port to measure pressure P aa PVPC with check valve P107 734E 45 SAUER PVG 32 S DANFOSS Service Manual 2 PVG 32 Component Troubleshooting Genuine Parts PVMR FRICTION MODULE Description Mechanical friction hold Location Mounted on main spool in the PVB Function Infinite mechanical positioning of the main spool Failure mode Cause Flow changes Excessive flow across the main spool Corrective action Reduce flow 100 l min or less Vibration Reduce vibration Broken spring Flow changes or will not stay in Check for proper assembly of parts detent Replace broken springs Install parts correctly per specification sheet PVMR module Plug x3 1 11 mm 4Nm Mechanical detent 35 lbfrin Screw x4 O5 mm 8 Nm 71 Ibfein 157 204 10 46 11039167 Rev AE gt November 2012 Z Plug N 36 mm 9 Z 15 Nm 133 Ibf in P107 811E PVG 32 S TO Service Manual PVG 32 Component Troubleshooting PVEO ON OFF Checking input control signal ELECTRICAL ACTUATOR CONTINUED 1 Install a volt meter to the ground pin connection and to the signal pin 2 Turn the power on for the electrical controller 3 Actuate the electrical controller and read the voltage 4 The control voltage should be per the electrical controll
10. 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 Caution Protect yourself from injury Use proper safety equipment including safety glasses at all times 11039167 Rev AE November 2012 13 SAUER DANFOSS OVERVIEW A Warning This troubleshooting guide for the PVG valve assemblies does not cover valves that have been altered from original valve build specifications TROUBLESHOOTING A PVG VALVE 14 PVG 32 Service Manual G System Troubleshooting Genuine Paris 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 observe the safety precautions listed in the Introduction section page 6 and related to your specific equipment Confirm that valve is built properly according to the specification sheet If necessary install a lever to the valve to verify proper mechanical function Refer to PVG 32 Technical Information Manual 520L0344 for
11. assembly P gt B gt F P gt A gt F Optional assembly Optional assembly 157 205 10 157 206 10 11039167 Rev AE November 2012 11 SAUER DANFOSS PVBS MAIN SPOOLS FOR FLOW CONTROL STANDARD PVBS MAIN SPOOLS FOR FLOW CONTROL WITH LINEAR CHARACTERISTICS PVBS MAIN SPOOLS FOR PRESSURE CONTROL 12 PVG 32 Service Manual G Operation cauma Part When using standard flow control spools the pump pressure is determined by the highest load pressure This is done either via the pressure adjustment spool in open center PVP fixed displacement pumps or via the pump regulator variable displacement pumps In this way the pump pressure will always correspond to the load pressure plus the stand by pressure of the pressure adjustment spool or the pump regulator This will normally give optimum and stable adjustment of the oil flow PVBS main spools with linear characteristic have less dead band than standard spools and a completely proportional ratio between control signal and oil flow in the range beyond the dead band A Warning PVBS with linear characteristic must never be used together with PVEM 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 In a few systems load sensing pump pressure may result in uns
12. damage Take oil sample Replace PVE 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 Low hydraulic oil supply Check signal pressure from the remote hydraulic controller Check fluid level in reservoir Repair or replace cylinder motor Fill reservoir with clean filtered fluid per OEM specification 11039167 Rev AE November 2012 19 S SAUER PVG 32 DANFOSS Service Manual HYDRAULIC OIL SUPPLY System Troubleshooting 5 Genuine Parts Cause Check Corrective action Pump not running Check prime mover for operation Repair or replace prime mover Check condition of drive coupling 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 Check for contamination and operation of relief valve Repair or replace relief valve Isolating valves are closed Check that all isolating valves are open and clear Faulty pump control Check pump compensator for correct operation and setting per pump manufacturers
13. pressure 11039167 Rev AE November 2012 3 SAUER DANFOSS PVG 32 COMPONENT TROUBLESHOOTING PVG 32 Service Manual G Contents Gainne Par Pressure relief Valve rennes Pressure reducing pilot valve Pressure gauge connection Open center plug ssssssssssssssesssssssssss Closed center plug and orifice Pressure adjustment SPOOL ctsssdacssciessaveossnsceetssocesnaxvectavevestavtectnadcesissceclaxsedasdiesravtertaaveedssscestasveetavivestaster LS connection ae LS SIgN aliens Shuttle Valve rennes LS pressure limiting ValVe sssssssssensrnnn sonnerie SA Be SPACE CS EAE EAEOI E EE EE AE EE EE E E Main spool lt Shock and anti cavitation valve PVLP rennes Pressure compensato secccsiveccstarcdesavecessavtecsnacestesovesnasvectuvevestovtectbucsessssconlasteesasdiessaeveqsaseedbdscesnenceensvvestesterh Load drop check valve nn Maximum oil flow adjustment screws for ports A and B PVM MOQUE nn a PVS Modules PVPVM MOQUE nn PVAS module PVPX LS unloading valve s s PVEH PVES PVEA electrical actuators was PVEO On Off electrical ACtUAtOM ce esssseccsssesccsseeecssseccessssecssseccsssescesssecesssecesssseecsssecessseseessseeessseessnseeees 11039167 Rev AE November 2012 SAUER DANFOSS OVERVIEW GENERAL INSTRUCTIONS PVG 32 Service Manual G Introduction enuie bart This manual includes information for servicing PVG 32 valves It includes a description of the units and their
14. valve configuration information Refer to PVG 32 Parts Manual 11006794 for part numbers THINK before troubleshooting a problem Every fault location process should follow a logical and systematic order It is wisest to start at the beginning Is the oil level correct when the pump is operating e Is the condition of oil and filters acceptable Are pressure flow and flow direction as specified Is the oil temperature too high or too low oil viscosity Are there any unusual vibrations or noise cavitation If the driver of the vehicle is available ask him What type of fault it is and how it affects the system How long he has felt that something has been wrong If he has fiddled with the components If he has any hydraulic and electrical diagrams available Diagrams are often found in the instructions included with vehicles machines Unfortunately they are often so technical that they are not of much use in a fault location situation However the diagram usually shows the order of and the connections between the individual components When a defective component is identified clean the component and its surroundings before removal Remove loose paint from pipes and fittings Cover all holes hoses and pipe ends with plugs or seal with for example plastic bags after removal to avoid the entry of dirt during repairs Never disassemble hydraulic components outside Perform repai
15. 6 a Do not try to adjust A G or disassenmble PVLP Q 13 mm 40 Nm a a in i P107 808E 40 11039167 Rev AE gt November 2012 SAUER DANFOSS PVAS MODULE PVG 32 Service Manual PVG 32 Component Troubleshooting Description Tie rod kit Location Through the valve stack Function Holds the stack together 5 Genuine Parts Failure mode Cause Corrective action Leaking externally between Tie rods under torqued Check and retorque 28 Nm 248 Ibfsin sections Tie rods torque too tight Replace and retorque 28 Nm 248 Ibfein If replacing seal kit replace tie rods also Sy ea te 3 bkin P107 817E 13 0 51 PVPX LS UNLOADING Description Optional two way two position solenoid VALVE REFER TO PAGE 13 FOR Location In the PVP VALVE OPERATION Function A safety device that dumps load sense to tank to prevent the pump from building pressure Failure mode Cause Corrective action Manual override leaking Not torqued correctly Check and retorque to 45 Nm 400 Ibf in externall x y High usage Replace per valve specification Manual override is bent Replace per valve specification Solenoid will not shift Coil not working Replace coil per valve specification Check with OHM meter 12 volt system 8 7 OHMs 24 volt system 33 OHMs Too high or too low of voltage Confirm voltage in system from remote controller 12 volt system should no
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17. Ibfein 5 Install new seal and install closed center plug Torque to 8 Nm 71 Ibfein 6 Install new O ring and install plug Torque to 35 Nm 130 Ibfein Closed center plug Plug 6 mm Z 35 Nm 308 lbf in O ring Bg Closed center plug Ya Pa 4mm Orifice Jo 8 Nm 70 Ibf in 2 5 mm 4 Nm 35 lbf in P107 737E 26 11039167 Rev AE gt November 2012 SAUER DANFOSS PRESSURE ADJUSTMENT SPOOL PVG 32 Service Manual G PVG 32 Component Troubleshooting Genuine fai 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 Low viscosity oil allowing high leakage around spool to tank Remove and clean orifice Reinstall High wear Replace compete module Serviceability Spool is not serviceable Replace complete module Pressure adjustment spool 11039167 Rev AE November 2012 P107 739E 27 SAUER PVG 32 DANFOSS Service Manual G PVG 32 Component T
18. Repair or replace pump per manufacturers procedure Optional pressure compensator in valve section not functioning Check compensator spool Replace spool Insufficient load pressure at compensator spring chamber LS drilling holes plugged Clean or replace Cylinder motor load too high for pressure setting of the system Check pressure at the valve If pressure is set to spec per valve lower load on cylinder motor Blocked LS galleries Inspect for blockage in LS galleries Remove blockage in LS galleries Shuttle valve faulty Inspect shuttle valve Repair or replace Blocked LS lines to pump controller Inspect LS lines from PCG to pump controller Remove blockage in LS lines from the PVG valve to pump controller Oil bypassing at shock valve anti cavitation check valve Check if stuck open or damaged Replace valve Internal leakage in cylinder motor Inspect for by passing of oil per cylinder motor manufacture per manufactures procedure Repair or replace cylinder motor per manufactures procedure Too much leakage in LS spool in pump control Check bleed orifice in LS control Use a LS pump control with no bleed orifice Blocked thermal orifice check thermal orifice blocked Replace thermal orifice Load too high for system Check for proper system pressure Adjust pressure to valve specification Internal leakage in cylinder motor Inspect for bypassin
19. S LS Unloading valve PVPC Plug for external pilot oil supply PVBS Main spool PVM Mechanical activation PVMD Cover for mechanical activation PVH Cover for hydraulic activation PVMF Cover for mechanical float PVMR Cover for friction detent PVMR or float position PVEH PVES PVEA Electrical activation PVEM Electrical activation PVEO Electrical activation 11039167 Rev AE November 2012 SAUER DANFOSS PVG 32 GROUP WITH OPEN CENTER PVP PVB WITH FLOW CONTROL SPOOL PVG 32 GROUP WITH CLOSED CENTER PVP PVB WITH FLOW CONTROL SPOOL PVG 32 Service Manual G Operation cauna Pai When the pump starts and the main spools in the individual basic modules 11 are in the neutral position oil flows from the pump through connection P across the pressure adjustment spool 6 to tank The oil flow led across the pressure adjustment spool determines the pump pressure stand by pressure When one or more of the main spools actuate the highest load pressure is fed through the shuttle valve circuit 10 to the spring chamber behind the pressure adjustment spool 6 and completely or partially closes the connection to tank 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 maintai
20. bavbuss0vesaasstssecbeldad nud civeotuctedsoadsovasszasduasdedeas 7 PVG 32 group with open center PVP PVB with flow control spool 8 PVG 32 group with closed center PVP PVB with flow control spool c ssesssseccsecssecsseeesseeese 8 PYG 32 sectional drawing svssissssssssssisssaessstusciacseoustessasteusssesavesssdunsventenustassiveasenierien PVPC plug for external pilot oil supply PVPC with check valve for open center PVP PVPC without check valve for open center PVP ren Friction d tenteurs PVMR Friction detente PVMF Mechanical float position 10Ck nr PVBS main spools for flow control standard PVBS main spools for flow control with linear characteristics PVBS main spools for pressure control nn 7 PVPX Electrical LS unloading valve OCE DARE E EN E EE EEEE EEN 14 Troubleshooting a PVG valve rennes 14 No cylinder motor response in either direction when remote controller is actuated 16 Cylinder motor responds in one direction only nn 16 Main valve spool moves without oil passing to cylinder motor 17 Cylinder motor operates without remote controller being operated 18 Cylinder motor responds slowly to remote electrical or hydraulic controller actuation 19 Erratic cylinder motor response to electrical or hydraulic controller operation 19 Hydraulic oil SUPPLY ire Electrical supply Hydraulic remote pilot control
21. ctrical controller Actuate the electrical controller and read the voltage The control voltage should be per the electrical controller output signal On electrical actuators coil resistance can not be measured at the pins When replacing an electrical actuator be sure that it has the same part number on it to ensure original functionality If filter in the electrical actuator has pieces of contamination trapped in it this is a good indication that the complete system is contaminated and needs to be flushed The filter in the electrical actuator can be removed and cleaned PVEA PVEH PVES Grey connector PVEA PVEH PVES Une Error Grey connector PVEA DI PVEH DI PVEA DI PVEH DI LU nn DI A DI B LED DI B DI A U DC2 Black connector PVEH PVES LED Float Error Grey connector 11039167 Rev AE November 2012 MUs PVEH PVES L Error m Upc LO Float
22. direction Assuming that the manual control lever and the main spool move freely both directions No control voltage from the electrical controller Ensure voltage from the electrical controller exists for that direction Lack of voltage to actuator Minimum voltage 11 volts for 12 volt system and 22 volts for 24 volt system Check system voltage Electrical actuator is defective Replace electrical actuator per spec on the valve Works intermittently if LED is green it indicates a long on off Loose connection between the electrical actuator and controller Repair connector Electrical actuator is defective Replace electrical actuator per spec on the valve Short in wiring harness Repair wiring harness 42 11039167 Rev AE November 2012 S AANE Service Manual PVEH PVES PVEA ELECTRICAL ACTUATORS CONTINUED PVG 32 PVG 32 Component Troubleshooting 5 Genuine Parts Failure mode Cause Corrective action Works with no command from controller Short in wiring harness Electrical actuator position feed back out of adjustment Repair wiring harness Replace the electrical actuator per valve spec Fine particulate contamination Replace PVE or electric actuator per valve specs Checking input control signal N Install volt meter to ground pin connection and signal pin with PVE in circuit Turn the power on for the ele
23. e pressure and PVB on tank line Maximum pressure Reduce system pressure Aluminum 300 bar 4500 psi Steel 350 bar 5000 psi PVS plugs PVSI SAN P107 707E For specifications and operating parameters on PVG 32 valves refer to PVG 32 Technical Information Manual 520L0344 11039167 Rev AE November 2012 39 SAUER PVG 32 S DANFOSS Service Manual G PVG 32 Component Troubleshooting Genuine Parts PVPVM MODULE 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 Uneven mounting surface and mounting Ensure the valve stack is mounted on a even surface and torque PVPVM and PVB screw torque down correctly Tie rods torqued too tight Replace tie rod kit which include section seals and torque to 28 Nm 248 lbf in Flow exceeding 61 gpm Lower flow to 61 gpm and replace the tie rod kit and seals Valve stack can not build Option PVLP shock valve not seating Install components correctly or replaced damaged components pressure per valve spec correctly in cavity caused by valve not being installed correctly or it has failed Flatness in millimeters T 0 35 mm X number of PVB modules 1 PVPVM module
24. eal washer and install cavity plug Torque to 35 Nm 130 lbf in Open center plug Plug 6mm e 35 Nm 308 lbf in Seal Qg center plug 3 mm 4 Nm 35 lbf in P107 736E 11039167 Rev AE November 2012 25 SAUER PVG 32 S DANFOSS Service Manual G PVG 32 Component Troubleshooting Genuine Parts CLOSED CENTER PLUG Description Plug that is installed in the inlet cover for a system with a variable AND ORIFICE displacement pump Location In the PVP module Inlet cover Function Allow connection for the load sense signal to the pump and provide connection to the main system relief valve Failure mode Cause Corrective action Valve operates at system relief Plug and orifice are not seated properly Reinstall orifice and torque to 4 Nm 35 Ibfeft using a 3 mm setting at all times internal hex wrench Reinstall plug and torque to 8 Nm 71 lbf in using a 8 mm internal hex wrench Can not adjust main relief above Orifice is plugged Remove and clean orifice Reinstall pump pressure setting of 30 Bar 450 psi Delta for closed inlet sections Serviceability Closed center plug and orifice are serviceable 1 Use a 6 mm internal hex to remove cavity plug from valve 2 Usea4mm internal hex to remove closed center plug 3 Usea2 5 mm internal hex to remove orifice 4 Clean or replace orifice Install orifice Torque to 4 Nm 35
25. ectly HYDRAULIC REMOTE PILOT CONTROL PRESSURE Cause Check Corrective action Insufficient pilot pressure Check pilot oil pressure 5 15 bar 72 220 psi delta between A and B port on remote 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 AE November 2012 21 SAUER DANFOSS PRESSURE RELIEF VALVE PVG 32 Service Manual 6 PVG 32 Component Troubleshooting Genuine Parts Description Adjustable relief valve Adjustment range 50 Bar 700 PSI to 350 Bar 5000 PSI Location The relief is i
26. ectrical controller Check voltage from the electrical controller is there for that direction Lack of voltage to actuator Minimum voltage 11 volts for 12 volt system and 22 volts for 24 volt system Check system voltage Electrical actuator is defective Replace electrical actuator per spec on the valve Works intermittently Loose connection between the electrical actuator and controller Repair connector Electrical actuator is defective Replace electrical actuator per spec on the valve Short in wiring harness Repair wiring harness Works with no command from controller Fine contamination Replace the electrical actuator per valve spec and flush the complete system and fill with filtered oil Short in wiring harness Repair wiring harness 44 11039167 Rev AE November 2012 SAUER DANFOSS PVPC PLUG FOR EXTERNAL PILOT CONTROL PVG 32 Service Manual PVG 32 Component Troubleshooting enuie fai 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 PVPC plug for external pilot LS 11039167 Rev AE November 2012
27. ed or restricted Disassemble valve Inspect passages for blockage 7 circuit 10 Serviceability Not serviceable Ensure entire system is clean LS circuit 10 Shuttle valve P107 815E 11039167 Rev AE November 2012 29 SAUER PVG 32 S DANFOSS Service Manual G PVG 32 Component Troubleshooting Genuine Parts SHUTTLE VALVE Description Self cleaning internal shuttle system Location PVB valve section module Function Determines which valve section is developing highest load pressure Failure mode Cause Corrective action Valve sections will not build Worn shuttle disc Replace complete module seat is pressed into module pressure NOTE Normally it Excessive air entrained in the hydraulic oil Ensure that the oil has enough dwell time in tank has will be one section but not all good anti foaming agent and pump inlet vacuum is within sections specifications Serviceability Not serviceable Ensure entire system is clean Shuttle valve Exploded view shows internal parts Ball should move Do not disassemble valve freely behind disk PVB Ball should move freely behind disk P107 804 30 11039167 Rev AE gt November 2012 SAUER DANFOSS LS PRESSURE LIMITING VALVE Failure mode PVG 32 Service Manual G PVG 32 Component Troubleshooting e
28. er output range Genuine Parts When replacing an electrical actuator be sure that it has the same part number on it to ensure original functionality PVEO PVEO R Grey connector PVEO DI LED Upc A DLE T U DC B dj DI A Cr D U cz Grey connector Black connector 11039167 Rev AE November 2012 Upc B PVEO PVEO R P107 812E 47 SAUER DANFOSS Products we offer e Bent Axis Motors e Closed Circuit Axial Piston Pumps and Motors e Displays e Electrohydraulic Power Steering e Electrohydraulics e Hydraulic Power Steering e Integrated Systems e Joysticks and Control Handles e Microcontrollers and Software e Open Circuit Axial Piston Pumps e Orbital Motors e PLUS 1 GUIDE e Proportional Valves e Sensors e Steering e Transit Mixer Drives Members of the Sauer Danfoss Group Comatrol www comatrol com Schwarzm ller Inverter www schwarzmueller inverter com Turolla www turollaocg com Hydro Gear www hydro gear com Sauer Danfoss Daikin www sauer danfoss daikin com 11039167 Rev AE November 2012 Sauer Danfoss is a global manufacturer and supplier of high quality hyd
29. f manual lever when electrical controller is operated If manual lever does not move check electrical voltage signal from controller wiring at the PVE module Check movement of manual lever when hydraulic controller is operated If manual lever does not move check hydraulic controller pressure at the PVG valve module 25 Bar 360 PSI If none of the above check pump per manufacturers recommended procedure Repair or replace pump per manufacturers recommended procedure Internal filters blocked Check for blockage in internal filters Remove blockage CYLINDER MOTOR RESPONDS IN ONE DIRECTION ONLY Cause Verify if fault is mechanical electrical or hydraulic Check Operate manual lever in both directions to confirm if mechanical or electrical or hydraulic Corrective action 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 Ibfsin Do not exceed maximum torque Check movement of manual lever when electrical controller is operated Check movement of manual lever when hydraulic controller is operated If manual lever does not move in one direction check electrical signal from controller and wiring at the PVE module If manual lever does not
30. flows to the pump regulator via the LS connection 8 In the neutral position the pump control sets the displacement so that leakage in the system is compensated to maintain the set stand by pressure When a main spool is actuated the pump regulator adjusts the displacement to maintain the set differential pressure between P and LS The pressure relief valve 1 in PVP should be set at a pressure of approximately 30 bar 435 psi above maximum system pressure set on the pump or external pressure relief valve 11039167 Rev AE November 2012 SAUER PVG 32 S DANFOSS Service Manual G Operation Genuine Parts PVG 32 SECTIONAL DRAWING PVP PVB PVB 157 104 11 1 Pressure relief valve 11 Main spool 2 Pressure reduction valve for pilot oil supply 12 LS pressure limiting valve 3 Pressure gauge connection 13 Shock and suction valve PVLP 4 Plug open centre 14 Pressure compensator 5 Orifice closed centre 15 LS 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 AE November 2012 9 SAUER DANFOSS PVPC PLUG FOR EXTERNAL PILOT OIL SUPPLY 10 PVG 32 Service Manual Operatio
31. g of oil per cylinder motor manufacturer specification Repair or replace cylinder motor Shock valve or anti cavitation check valve faulty Inspect for damage and contamination Repair or replace cylinder motor System relief valve pressure set too low for load Install pressure gauge and check pressure Adjust pressure to system specification Lower load Cylinder motor load too high for pressure settings of system Check load pressure at PVB LS port Reduce load pressure if exceeds maximum pressure limit of the system Maximum system pressure should be approx 25 Bar 365 PSI above highest load pressure Adjust maximum system pressure if necessary Adjust pump pressure compensator setting if necessary 11039167 Rev AE November 2012 17 S SAUER PVG 32 DANFOSS Service Manual System Troubleshooting 5 Genuine Parts CYLINDER MOTOR OPERATES WITHOUT REMOTE CONTROLLER BEING OPERATED Cause Check Corrective action Spool control tension rod loose Confirm torque on spool control tension rod Torque to 8 Nm 70 Ibfein Electrical feedback transducer not in neutral position Check the feedback pin in the PVE It should be loose Replace 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 Stickin
32. g 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 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 Replace the valve module and main spool if any damage is found on the main spool Internal fault in the PVE PVEH PVEM PVEO PVEO check continuity All other PVE check LED Red means internal error Replace faulty PVE PVEH PVEM PVEO Contamination in the hydraulic oil Take oil samples to confirm Flush hydraulic system Fill with clean filtered oil 18 11039167 Rev AE gt November 2012 SAUER DANFOSS CYLINDER MOTOR RESPONDS SLOWLY TO REMOTE ELECTRICAL OR HYDRAULIC CONTROLLER ACTUATION PVG 32 Service Manual System Troubleshooting Genuine Parts 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 Refer to Component troubleshooting section page 22 Adjust the manual lever stops and torque the
33. ghest temperature in the system If one PVE section is operated more frequently than others this would create more heat than any other part of the valve Under these conditions it is extremely important to insure that the hydraulic system is well cooled Oil temperature measurements at the reservoir and at the center of the PVG32 valve stack The valve should be mounted to provide the best ventilation for the PVE electronics Poor filtration and low fluid levels may also add to temperature Failure mode Cause Corrective action Does not work in either direction LED is green No control voltage from the electrical controller Check voltage from the electrical controller 25 to 75 of supply Command pin wire in mating connector is broken Repair broken wire Connector corroded This condition is caused by water ingression or ground connection Replace PVE and mating connector Does not work in either direction LED is off No power from the battery Check power to electrical actuator Power pin wire in mating connector is broken Repair broken wire Connector corroded This condition is caused by water ingression or ground connection Replace PVE and mating connector Ground connection must be hard wired straight from the battery or from the electrical controller Repair ground connection LED is flashing Red Control signal is out of range Check wiring harness for short Works in one
34. he 4 mounting screws to 8 Nm 70 Ibfsin If section does not build pressure in one direction wrong spool may have been installed in valve Main spool Screw 11 mm ze 8Nm 70 lbf in P107 805E 3 11039167 Rev AE November 2012 33 SAUER DANFOSS SHOCK AND ANTI CAVITATION VALVE PVLP PVG 32 Service Manual G PVG 32 Component Troubleshooting Genuine Parts 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 port Valve may be damaged and not able to seal Replace with correct part number per valve specification 34 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 PVLP valve 310 Ibfsin Plug o 13 mm 36 Nm Do not try to adjust or disassemble PVLP P107 743E 11039167 Rev AE November 2012
35. individual components troubleshooting information and minor repair procedures Performing minor repairs may require removal from the vehicle machine Thoroughly clean the unit before beginning maintenance or repair activities Since dirt and contamination are the greatest enemies of any type of hydraulic equipment follow cleanliness requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide network of Sauer Danfoss Global Service Partners is available for major repairs Sauer Danfoss trains and certifies Global Service Partners on a regular basis You can locate your nearest Global Service Partner using the distributor locator at www sauer danfoss com For specifications and operating parameters on PVG 32 valves refer to PVG 32 Technical Information Manual 520L0344 Do not attempt to service PVG valves without build sheet specifications for reference Follow these general procedures when repairing PVG 32 valves Al Remove the unit Chock the wheels on the vehicle or lock the mechanism to inhibit movement Prior to performing repairs remove the unit from the vehicle machine Be aware that hydraulic fluid may be under high pressure and or hot Inspect the outside of the valve stack and fittings for damage Cap hoses after removal to prevent contamination A Keep it clean Cleanliness is a primary means of assuring satisfactory motor life on either new
36. jam nuts to 8 Nm 70 lbf 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 LS 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 Electrical actuator faulty Check Check signal from controller to PVE Corrective action Repair or replace PVE Main spool centering spring damaged Check tension rod for correct torque or damage Torque to 8 Nm 70 Ibfein or replace Main spool position feedback transducer signal incorrect Contamination in hydraulic oil Check feedback pin for
37. lvents are flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present Fluid under pressure A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection This fluid may also be hot enough to cause burns Use caution when dealing with hydraulic fluid under pressure Relieve pressure in the system before removing hoses fittings gauges or components Never use your hand or any other body part to check for leaks in a pressurized line Seek medical attention immediately if you are cut by hydraulic fluid Personal safety A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times Hazardous material A Warning Hydraulic fluid contains hazardous material Avoid prolonged contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations 11039167 Rev AE November 2012 SAUER PVG 32 S DANFOSS Service Manual G Introd uction Genuine Parts ACRONYMS This table provides a definition of commonly used terms P Proportional V Valve PVP Pump side module PVPV M Pump side module PVB Basic module PVLA Anti cavitation valve PVLP Shock and anti cavitation valve PVS PVSI End plate PVAS PVP PVPV M Assembly kit for PVP PVPV M PVPX L
38. millimeters T 0 35 mm X number of PVB modules 1 11039167 Rev AE November 2012 SAUER DANFOSS MAIN SPOOL CONTINUED PVG 32 Service Manual 6 PVG 32 Component Troubleshooting ets 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 3 Flush out openings into the main spool cavity at each end 4 Install plug with a 11 mm or 12 mm open end wrench Torque to 8 Nm 70 Ibfein 5 Install centering spring and tension rod using a 13 mm open end wrench and torque to 8 Nm 70 Ibfsin 6 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 7 Install a manual actuator Reassemble in reverse order and torque t
39. 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 Shock valves Excessive internal leakage may overheat the system Swap and see if problem follows Install loop flushing defeat option and monitor case flow If case flow is excessive motor may require major repair Contact Sauer Danfoss Service Replace valves Solenoid actuation If power is OK from controller Repair wiring to PVE module Main spool travel restricted Remote electrical controller Stop on manual controller turned in too far Insufficient signal from electrical controller Back out manual stop on manual controller Repair or replace electrical controller PVEO connections Incorrect PVE PVEO connections Connect correct way Remote hydraulic controller PVRH 16 Insufficient pilot oil pressure from remote hydraulic controller Pressure needs to be 25 Bar 360 psi 11039167 Rev AE November 2012 Repair or replace remote hydraulic controller S SAUER PVG 32 DANFOSS Service Manual System Troubleshooting 5 Genuine Parts MAIN VALVE SPOOL MOVES WITHOUT OIL PASSING TO CYLINDER MOTOR Cause Check Corrective action Insufficient oil supply to valve Check the pump per manufacturers procedure
40. n Genuine Parts PVPC with check valve for open center PVP PVPC with check valve is used in systems where it is necessary to operate the T P PVG 32 valve by means of the electrical remote control without pump flow yO When the external solenoid valve is T 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 Oil Flow Direction LS O ne ayo ww i 157 114 11 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 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 froma 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
41. n all PVP Inlet modules Function Provides maximum pressure setting above pump pressure setting 30 Bar 450 PSI Delta for open center and closed inlet sections Failure mode Cause Corrective action Will not build pressure 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 Replace valve External leaking Damaged seat and poppet Replace complete assembly Pressure setting is wrong Pressure adjustment backs off on open Adjust to model code specification center application Instability when PC and inlet relief has too low of a delta between them PC at pump should be set 20 bar below Adjust to model code specification relief valve PRESSURE REDUCING PILOT VALVE 22 Serviceability Non serviceable Valve removal tool P N 155L6485 Torque to 20 Nm 180 Ibfein Description Pressure reducing valve at fixed pressure Location The pressure reducing valve is a option in some PVP Inlet modules Function Provides 10 15 bar 145 218 psi internal pressure for electrical PVE actuators or provide 25 Bar 360 PSI PVHC and supply for external remote hydraulic actuators HRC These pressures are only present when the load pressures are high enough to satisfy the required regulated pressure The open center system at low pump flow may only develop 9 Bar 130 PSI 11039167 Rev AE November 2012
42. ns 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 Bare 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 In the closed center version an orifice 5 and a plug 7 are fitted instead of the plug 4 This means that the pressure adjustment spool 6 only opens to tank when the pressure in channel P exceeds the set value of the pressure relief valve 1 In LS systems the load pressure
43. nuie Pai 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 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 Pressure adjustment backs off Low cartridge torque Torque to 20 Nm 177 Ibfein maximum Replace complete assembly 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 Ibfein 11039167 Rev AE November 2012 31 SAUER DANFOSS LS A B SHUTTLE PVG 32 Service Manual S PVG 32 Component Troubleshooting Genuine Parts 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 Failure mode Cause Corrective action Will not build pressure in A or B Contamination preventing shut
44. onents 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 Pressure reducing pilot valve can be removed from the cavity cleaned inspected and reassembled back into the valve 1 Usea6mm 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 Ibfsin use an M5 screw to install spool 11039167 Rev AE November 2012 wre Plug 6 mm Na 25 Nm 220 lbf in O O ring fa Spool Cone Li Spring P107 733E 23 SAUER PVG 32 S DANFOSS Service Manual 2 PVG 32 Component Troubleshooting Genuine Parts PRESSURE GAUGE Description Port to install a pressure gauge to check pressure relief valve setting to CONNECTION valve specification Location On inlet cover to valve stack 1 Use 6 mm internal hex to remove and install plug 2 Torque plug to 35 Nm
45. or repaired units Clean the outside of the valve thoroughly before disassembly Take care to avoid contamination of the port connections on the valve stack Clean parts using a clean solvent wash and air dry As with any precision equipment keep all parts free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material If left unattended cover the valve with a protective layer of plastic il Replace all O rings and gaskets Sauer Danfoss recommends you replace all O rings Lightly lubricate all O rings with clean petroleum jelly prior to assembly A Secure the unit For repair place the unit in a stable position with the shaft pointing downward Secure the motor while removing and torquing controls and valves 11039167 Rev AE November 2012 5 SAUER DANFOSS SAFETY PRECAUTIONS PVG 32 Service Manual G Introd uction Genuine Parts Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take the following general precautions whenever servicing a hydraulic system Unintended machine movement A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Flammable cleaning solvents A Warning Some cleaning so
46. raulic and electronic components We specialize in providing state of the art technology and solutions that excel in the harsh operating conditions of the mobile off highway market Building on our extensive 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 market faster Sauer Danfoss Your Strongest Partner in Mobile Hydraulics Go to www sauer danfoss com for further product information Wherever off highway vehicles are at work so is Sauer Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with an extensive network of Global Service Partners we also provide comprehensive global service for all of our components Please contact the Sauer Danfoss representative nearest you Local address Sauer Danfoss US Company Sauer Danfoss ApS 2800 East 13th Street DK 6430 Nordborg Denmark Ames IA 50010 USA Phone 45 7488 4444 Phone 1515 239 6000 Fax 45 7488 4400 Fax 1515 239 6618 Sauer Danfoss GmbH amp Co OHG Sauer Danfoss Daikin LTD Postfach 2460 D 24531 Neum nster Shin Osaka TERASAKI 3rd Bldg 6F Krokamp 35 D 24539 Neum nster Germany 1 5 28 Nishimiyahara Yodogawa ku Phone 49 4321 8710 Osaka 532 0004 Japan Fax 49 4321 871 122 Phone 81 6 6395 6066
47. roubleshooting Genuine Parts LS CONNECTION Description Port for LS signal for LS static option only controller for variable flow pump Location PVP inlet module Function Provide a signal to the variable pump controller to create a pressure differential to have the pump come on stroke for a closed center system Failure mode Cause Corrective action In closed center systems the Insufficient LS flow to satisfy pump Ensure that the LS controller on the pump does not have valve sections are unstable controller excessive internal leakage 0 4 I min 0 106 gal min Repair or replace the variable pump controller per pump manufactures specifications If there is more than one valve in the system ensure that the LS shuttles are all working properly Excessive air entrained in the hydraulic oil Ensure that the oil has enough dwell time in tank has good anti foaming agent and pump inlet vacuum is within manufacturers specifications Air trapped in LS line Bleed air for LS line at highest point Valve operation is slow to Insufficient LS flow to satisfy pump If more than one section ensure that the LS controller on the respond or does not respond controller pump does not have excessive internal leakage Repair or replace the variable pump controller per pump manufactures specifications Excessive air entrained in the hydraulic oil Ensure that the oil has enough dwell time in tank has good anti foaming agent and pump inlet
48. rrective action Load drops excessively when Worn parts Replace complete PVB module trying to lift load Hard particle in seat area does not allow the Replace complete module seat to seal Serviceability Load drop check valve is not serviceable If you suspect valve malfunction replace complete module Load drop check valve O T T Ca US SU O IW _ Load drop check valve P107 747E Load drop check valve P107 748E 36 11039167 Rev AE gt November 2012 SAUER DANFOSS MAXIMUM OIL FLOW ADJUSTMENT SCREWS FOR PORTS A AND B PVG 32 Service Manual G PVG 32 Component Troubleshooting ets 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 or too fast Mechanical stop screws out of adjustment Use a 8mm open end wrench to loosen the jam nut and then per valve spec 3mm 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 Ibfsin Retorque or replace seal nuts Caution When adjusting main spool flow ensure that electrical or h
49. rs in a workshop on a clean workbench covered with clean cloth or newspaper Make sure that a Sauer Danfoss service manual for with the product is handy Follow the instructions word for word during disassembly and assembly If these instructions are not followed closely the system may not operate correctly after repairs are completed Note that in some cases special tools are necessary for assembling the product Our service manuals give full guidance on use of special tools 11039167 Rev AE November 2012 PVG 32 S Soe Service Manual System Troubleshooting Troubleshooting flow chart P107 823 11039167 Rev AE November 2012 15 SAUER PVG 32 DANFOSS Service Manual G Genuine Parts System Troubleshooting NO CYLINDER MOTOR RESPONSE IN EITHER DIRECTION WHEN REMOTE CONTROLLER IS ACTUATED Cause Check Corrective action Verify if fault is mechanical electrical or hydraulic Operate manual lever to confirm mechanical or electrical or hydraulic If moving the manual lever operates the cylinder motor check electrical or hydraulic Sticking main spool 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 and it should move freely in the valve section bore Replace the valve module and main spool If any damage is found on the main spool Check movement o
50. t exceed 13 2 volts 24 volt system should not exceed 26 4 volts 11039167 Rev AE November 2012 41 SAUER DANFOSS PVEH PVES PVEA ELECTRICAL ACTUATORS PVG 32 Service Manual PVG 32 Component Troubleshooting SG Genuine Parts 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 Troubleshooting considerations Wiring Check It is highly possible that in the case of one PVE failing that there could be a poor connection between the joystick and the PVE in question The PVE is reverse polarity protected and suppression protected however an intermittent connection could degrade the input electronics to a point of failure Inspect all wiring and connectors for corrosion and or pinch points Hirshman Receptacle and Mating Connector Each PVE is supplied with a field installable 4 pin Hirshman mating connector and gasket It is recommended that the gasket be installed between the mating connector and PVE receptacle also the rubber grommet be sealed around a multi wire jacket in order to seal off moisture from the wiring connections The PVE is rated for IP65 only when the Hirshman connector is sealed Temperature Capability The PVE is rated for 1000 hours 160 F ambient temperature Oil temperature wise the area of the valve that creates the highest horsepower loss usually creates the hi
51. table h adjustment of the oil flow and a psi bar 4 tendency towards system hunting This j may be the case with working functions 250 that have a large moment of inertia 30007 200 or over center valves In such systems 2000 150 main spools for pressure control can be ioo 100 advantageous The spools are designed 50 PVBS in such a way that the pump pressure is om ba ee o controlled by the spool travel The main spool must be displaced until the pump 0 005 010 015 020 025 m pressure just exceeds the load pressure 0 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 e the dead band is load dependent the pump pressure can exceed the load pressure by more than is usual 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 LS when pressure stability is an issue 11039167 Rev AE November 2012 SAUER DANFOSS PVPX ELECTRICAL LS UNLOADING VALVE PVG 32 Service Manual 6 Operation Genuine Par 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
52. tle ball from Replace complete PVB module work port building load sense relief pressure LS A B shuttle aap e 5 z H N Io OE Ii poo sj l L l l Be ls Shuttle O r Ol bail P IL Ly 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 Load sense passages in spool are blocked Flush out load sense passages in the spool Spool will need one spool direction to be removed to clean Main valve spool stuck in valve Refer to Pressure reducing valve section Replace PVM and PVE Be sure that pilot valve is assembled body if being used with electrical page 22 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 spool stuck in valve body can 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 lbf in Valve stack mounting surface is not flat Ensure the mounting surface is flat causing a bind on the valve stack 32 Flatness in
53. vacuum is within specifications Air trapped in LS line Bleed air for LS line at highest point PVG valve is mounted above hydraulic oil reservoir when shut down and sits idle for some time the valve could be voided of oil and this would cause the valve to operate erratically and be slow to respond Serviceability Port is serviceable Need to connect hose to LS port on pump LS connection plug LS Plug 6 mm 35 Nm 308 lbf in P107 740E 28 11039167 Rev AE November 2012 SAUER DANFOSS LS SIGNAL PVG 32 Service Manual 6 PVG 32 Component Troubleshooting ets Description The PVG32 uses an internal LS signal network for both Open Center and Closed Center systems In Open Center systems the internal LS signal network provides a resolved load sense signal to the pressure adjustment spool controlling the proper amount of flow and pressure to the operating valve sections In Closed Center systems the internal LS signal network provides a resolved load sense signal directly to the LS pump control which in turn provides the proper amount of flow and pressure to the operating valve sections Location PVP PVB Modules Function Directs the highest load pressure to either OC or CC pump control to satisfy the operating valve section Failure mode Cause Corrective action No pump pressure developed in one or more valve sections LS passages block
54. ydraulic actuators are not active at the time if so equipped Adjusting screws for ports A and B For standard mount top adjusting screw is B and bottom adjusting screw is A P107 816E 11039167 Rev AE November 2012 37 SAUER PVG 32 S DANFOSS Service Manual G PVG 32 Component Troubleshooting Genuine Parts 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 Replace PVM module seals and lower tank port pressure and PVB on tank line TO port not connected to tank or restricted Connect to tank remove restriction and remove blockage or blocked PVM module QG Screw x4 5mm Ze 8 Nm 70 lbfein P197 806E 38 11039167 Rev AE gt November 2012 PVG 32 S ae Service Manual PVG 32 Component Troubleshooting Genuine Parts 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 Replace PVS module seals and lower tank lin
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