Danfoss OSPE Service Manual Download

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MAKING MODERN LIVING POSSIBLE

Service Manual

Steering Valve

OSPE

powersolutions.danfoss.com

Summary of Contents for OSPE

Page 1: ...MAKING MODERN LIVING POSSIBLE Service Manual Steering Valve OSPE powersolutions danfoss com ...

Page 2: ...Revision history Table of revisions Date Changed Rev August 2015 Codenumber changed 0001 February 2015 First edition AA Service Manual OSPE Steering Valve 2 L1506577 Rev 0001 August 2015 ...

Page 3: ...E Set up for testing 42 Set up OSPE with integrated priority valve 42 Set up OSPE without integrated priority valve 43 Steering test 43 Pilot relief valve 44 Neutral positioning test OSP part 44 Neutral positioning test EH part 44 Manual steering 44 Shock valves 44 OSPE LSRM 44 OSPE LS non reaction non reaction versions 44 Check for external leakage 45 Tightening Torques Tightening torques for con...

Page 4: ... 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 W Warning Personal Safety Protect yourself from injury Use proper sa...

Page 5: ...OSPED with dual gear set For the gear set end however only for V2 OSPED in new design If the OSPED in question is in old or V2 new design can be traced by the product code OSPED s with product code number higher than 11113069 are all in new design OSPED s with product code lower than 11113069 are all in old design For further explanations between OSPED in old and new design see Product Information...

Page 6: ...42 332 331 330 232 203 230 231 215 214 213 247 246 254 312 314 253 204 233 233 P301 786 93 95 300 301 302 34 30 116 122 117 115 120 39 303 304 305 34 30 36 31 35 39 36 31 27 35 323 322 321 14 7 18 16 1 81 80 209 6 311 OSPE DEUTSCH AMP DEUTSCH AMP CLS OSPED Service Manual OSPE Steering Valve Exploded View and Seal Kit 6 L1506577 Rev 0001 August 2015 ...

Page 7: ...D 6 39 O ring Ø79 4 x Ø2 0 mm OSPE 2 39 O ring Ø9 0 x Ø1 5 mm 2 40 O ring Ø6 0 x Ø1 5 mm 2 41 Balls for shock valves Ø4 8 mm 2 61 Spring with thrust pad for shock valves 2 62 Valves seats 2 63 5 5 0 5 Nm Adjusting screws for shock valves 2 64 Pins 2 80 3 0 5 Nm Balls for suction valves Ø4 8 mm 2 81 Screw 1 85 1 5 0 3 Nm Spring 1 86 Valve cone for P check 1 87 Plug 1 93 Pilot relief valve cartridge...

Page 8: ...mp 1 246 15 2 Nm Coil 1 247 Nut 1 248 5 1 Nm O ring Ø10 0 x Ø1 5 mm 1 249 Plug 1 253 20 3 Nm Plug 1 254 20 3 Nm Lock ring 1 300 O ring Ø7 5 x Ø1 5 mm 1 301 O ring Ø11 0 x Ø2 0 mm 1 302 Backup ring 1 303 O ring Ø8 0 x Ø1 5 mm 1 304 Filter 1 305 O ring Ø23 3 x Ø2 4 mm 1 310 O ring Ø17 8 x Ø2 1 mm 2 311 O ring Ø17 4 x Ø2 1 mm 2 312 O ring Ø15 0 x Ø1 5 mm 1 313 O ring Ø11 0 x Ø2 0 mm 1 314 O ring Ø10 ...

Page 9: ...0N4041 6 7 9 35 39 40 41 Seal kit OSPE EH part 11160415 93 225 310 311 312 313 314 Seal kit Pilot relief valve cartridge 155L6870 300 301 302 303 304 305 Seal kit PVE 157B4997 320 321 322 323 Seal kit Cartridge spool for pilot dump 120433 330 331 332 Spare parts list Code No Containing seal kits codes Seal kit KIT OSPE complete 11160838 150N4041 11160415 155L6870 157B4997 120433 Service Manual OSP...

Page 10: ... Material Free cutting steel This tool is not available from Danfoss 0 5x45 ø26 0 1 min ø40 min 35 100 5 P301 643 Assembly tool for shaft seal O ring Roto Glyd type Code number 11092408 This tool has been modified by January 2015 The upper end of outer tube has knurled surface on 25 mm from top only was 35 mm Tool with 35 mm knurled surface can be modified by grinding off 10 mm of the knurled surf...

Page 11: ...ch 0 70 Nm 13 17 19 and 32 mm socket spanner 2 2 75 3 4 5 6 and 8 mm Hex key 12 mm screwdriver 2 mm screwdriver 13 17 19 7 8 inch mm ring spanner Inside circlip pliers Plastic hammer Tweezers These tools are not available from Danfoss Service Manual OSPE Steering Valve Tools L1506577 Rev 0001 August 2015 11 ...

Page 12: ...he PVE 233 using a 5 mm Hex key Remove the PVE 204 O rings 320 321 322 and filter 323 are fitted to the mounting surface of PVE Screw out the plug 243 using a 17 mm socket or ring spanner O ring 312 is fitted on plug 243 Remove the spring 241 Service Manual OSPE Steering Valve Dismantling 12 L1506577 Rev 0001 August 2015 ...

Page 13: ...et or ring spanner O ring 312 is fitted on plug 207 If the OSPE is without priority valve integrated Use a 8 mm Hex key This plug is fitted with O ring 312 and 313 Remove the spring 231 Remove the priority valve spool 203 Orifices 230 and 232 are screwed into spool 203 Service Manual OSPE Steering Valve Dismantling L1506577 Rev 0001 August 2015 13 ...

Page 14: ...socket or ring spanner Remove the O ring 249 Lift off the coil 247 Screw out the cartridge spool 246 using a 7 8 inch ring spanner O rings 330 331 332 are fitted on cartridge spool 246 Service Manual OSPE Steering Valve Dismantling 14 L1506577 Rev 0001 August 2015 ...

Page 15: ...under the mounting surface for the PVE to support the steering valve Screw out the adjusting screws for shock valves 64 using a 5 mm Hex key O ring 40 is fitted on screw 64 Remove the springs with trust pads for shock valves 62 Remove the balls for shock valves 61 Service Manual OSPE Steering Valve Dismantling L1506577 Rev 0001 August 2015 15 ...

Page 16: ...panner O ring 310 is fitted on plug 205 Remove the EH spool 202 Screw out the plugs 209 using an 8 mm Hex key O ring 311 is fitted on plug 209 The left side positioned plug is only present on OSPE s with priority valve integrated Replace the unit in the holding tool on steering column end Service Manual OSPE Steering Valve Dismantling 16 L1506577 Rev 0001 August 2015 ...

Page 17: ...ef valve 95 Screw out the pilot relief valve cartridge 95 using special key Danfoss code 155L6494 Screw out the orifice 222 using a 3 mm Hex key This orifice is not present in all OSPE s Service Manual OSPE Steering Valve Dismantling L1506577 Rev 0001 August 2015 17 ...

Page 18: ...Screw out the plugs 253 and 254 using a 6 mm Hex key These plugs not present in all OSPE s OSPED Remove the screws 1x27 and 6x31 with washers 35 using a 13 mm socket or ring spanner OSPE Has 7 identical screws 7x 31 Remove the end cover 36 sideways Service Manual OSPE Steering Valve Dismantling 18 L1506577 Rev 0001 August 2015 ...

Page 19: ... the two O rings 39 OSPED Remove the distributor plate 117 OSPED Remove valve housing assembly 122 Remove the two O rings 39 Do not dismantle the entire valve 122 OSPED Remove the distributor plate 116 Service Manual OSPE Steering Valve Dismantling L1506577 Rev 0001 August 2015 19 ...

Page 20: ...the cardan shaft 120 Lift the gearwheel set 30 off the unit Remove the two O rings 39 Remove the cardan shaft 13 Remove the distributor plate 34 from the housing Service Manual OSPE Steering Valve Dismantling 20 L1506577 Rev 0001 August 2015 ...

Page 21: ...ushing ball stop 4 from housing using a 12 mm screw driver and remove bushing from housing Screw out the screw 85 using a 12 mm screw driver Spring 86 and valve cone 87 will be attached to the screw 85 Service Manual OSPE Steering Valve Dismantling L1506577 Rev 0001 August 2015 21 ...

Page 22: ...ew out the pin bolts 80 using a 4 mm Hex key Screw out the plug 216 using a 6 mm Hex key O ring 314 is fitted on plug 216 Remove plug 216 and spool 215 Service Manual OSPE Steering Valve Dismantling 22 L1506577 Rev 0001 August 2015 ...

Page 23: ... suction valve balls 81 cone 214 and spring 213 Place the housing with the ports facing down on the work bench Ensure that the cross pin 12 in the spool and sleeve set 1 is in the horizontal position The pin 12 can be observed through the open end of the spool Service Manual OSPE Steering Valve Dismantling L1506577 Rev 0001 August 2015 23 ...

Page 24: ... out of the housing together Take the bearing races with needle bearing 18 and the ring 16 off from the spool and sleeve set 1 The outer bearing 18 race can sometimes stick in the housing therefore check that it has come out Press out the cross pin 12 Carefully press the spool out of the sleeve Service Manual OSPE Steering Valve Dismantling 24 L1506577 Rev 0001 August 2015 ...

Page 25: ...crew driver or similar tool The steering unit OSPED is now completely dismantled Cleaning Clean all parts carefully in Shellsol K or similar cleaner fluid Inspection and replacement Replace all seals and washers Check all parts carefully and make any replacements as is necessary Service Manual OSPE Steering Valve Dismantling L1506577 Rev 0001 August 2015 25 ...

Page 26: ...n of spring set There can be 2 4 or 6 curved springs 150 386 10 OSPEF Spool and sleeve must be positioned correctly relatively to each other Small marks are present on both spool and sleeve close to one of the slots for the spring set 150 412 10 Guide the spool into the sleeve 1 If the spool and sleeve has marks as shown above these must be placed on same side Make sure the neutral position spring...

Page 27: ...6 down over the sleeve The ring should be able to move free of the springs Fit the cross pin 12 into the spool sleeve set 1 Fit bearing races and needle bearing 18 as shown on the drawing below Service Manual OSPE Steering Valve Assembly L1506577 Rev 0001 August 2015 27 ...

Page 28: ...own on the work bench Guide the outer part of the assembly tool into the bore for the spool sleeve set 1 Grease the shaft seal Roto Glyd 7 with hydraulic oil and place them on the tool Ensure that the Roto Glyd seal is placed on the insertion tool as per the photograph Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to ...

Page 29: ...he inner part in the bore With a light turning movement guide the spool and sleeve into the bore Fit the spool set holding the cross pin 12 horizontal The spool set will push out the assembly tool guide The shaft seal 7 is now installed Place the steering valve housing 3 on the holding tool on the steering column end Service Manual OSPE Steering Valve Assembly L1506577 Rev 0001 August 2015 29 ...

Page 30: ...crew driver 1 5 0 3 Nm Assemble spring 86 and cone 87 on screw 85 Place the assembly in the hole indicated by the circle Screw in the screw 85 using a 12 mm screw driver 1 5 0 3 Nm Put the suction valve balls 81 into the holes indicated by the circles Service Manual OSPE Steering Valve Assembly 30 L1506577 Rev 0001 August 2015 ...

Page 31: ...in the pin bolts 80 using a 4 mm Hex key 3 0 5 Nm Place the spool 224 in the hole indicated by the circle Screw in the plug 225 using a 5 mm Hex key 10 2 Nm Service Manual OSPE Steering Valve Assembly L1506577 Rev 0001 August 2015 31 ...

Page 32: ...the spring 213 cone 214 and spool 215 in the hole indicated by the circle Place the O ring 314 on plug 216 Screw in the plug 216 using a 6 mm Hex key 30 3 Nm Service Manual OSPE Steering Valve Assembly 32 L1506577 Rev 0001 August 2015 ...

Page 33: ...t is parallel with the connection flange for P T L and R ports and lines up with the cross pin 12 Place the 2 O rings 39 in the two groves in the gear rim Fit the gearwheel with rim 30 on the cardan shaft 13 Place the gear wheel side with all the deeper splines facing downwards Only this side will fit on the cardan shaft due to all gear sets used in OSPE have timing securing splines of gear wheel ...

Page 34: ...e holes in the gear set OSPED Place the 2 O rings 39 in the two groves in the valve housing assembly 122 Place the valve housing assembly so that the one and only M8 thread whole points upwards and direction port face for P T L and R connections Make sure that channel holes of the valve housing assembly 122 match the holes in the distributor plate 116 Service Manual OSPE Steering Valve Assembly 34...

Page 35: ...haft can only be assembled with correct timing Place the end cover 36 in position Ensure that the bar codes and writing are parallel with the port face for P T L and R connections OSPED Fit the short screw 27 with washer 35 and place it in the hole indicated by circle OSPED Fit the six screws 31 with new washers 35 and insert them Cross tighten all the screws 27 and 31 using a 13 mm socket spanner...

Page 36: ...dust seal ring 9 in the housing using special tool for dust seal assembly see page 7 and a plastic hammer Place O ring 41 on the shock valve seats 63 Screw in the seats 63 using a 2 75 mm Hex key into the cavities indicated by the circles 6 1 Nm 53 1 8 85 lbf in Place one ball 61 in each of the shock valve cavities Service Manual OSPE Steering Valve Assembly 36 L1506577 Rev 0001 August 2015 ...

Page 37: ...g a 5 mm Hex key After entire assembly of the steering valve make the pressure setting on a test panel according to valve setting specification see Shock valves on page 44 Insert the EH spool 202 Place O ring 310 on plug 205 Screw in the plug 205 using a 32 mm socket spanner 45 5 Nm Service Manual OSPE Steering Valve Assembly L1506577 Rev 0001 August 2015 37 ...

Page 38: ...ge 95 Screw in cartridge 95 using special key Danfoss code 155L6494 20 3 Nm After entire assembly of the steering valve make the pressure setting on a test panel according to valve setting specification see Shock valves on page 44 Insert plastic protection plug 93 Screw in the LS check valve 221 using a 3 mm Hex key 3 0 5 Nm This check valve is not present in all OSPE s Screw in the orifice 222 us...

Page 39: ...r 15 2 Nm OSPE with priority valve Assemble spool 203 with the PP orifice 230 using a 3 mm Hex key 3 5 0 5 Nm And with dynamic orifice 232 using a 2 mm Hex key 1 0 1 Nm Insert the priority valve spool 203 with the spring bore pointing outwards OSPE with priority valve Insert the spring 231 Dimension of this spring depends on specification of priority valve Service Manual OSPE Steering Valve Assemb...

Page 40: ... on plug 207 with 8 mm Hex key profile Screw in the plug 207 using a 8 mm Hex key 45 5 Nm Insert the EH L R cut off spool 242 with the spring bore pointing outwards Insert the spring 241 Dimension of this spring Wire diameter 2 2 mm Length 50 2 0 8 mm Place the O ring 312 on plug 243 Screw in the plug 243 using a 17 mm socket spanner 45 5 Nm Service Manual OSPE Steering Valve Assembly 40 L1506577 ...

Page 41: ...e PVE 204 on OSPE housing as illustrated and screw in the 4 screws for the PVE 233 using a 5 mm Hex key 8 1 Nm Place coil 247 on cartridge for pilot dump 246 Place O ring 249 and nut 248 on cartridge for pilot dump 246 Screw in the nut 248 using a 19 mm socket spanner 5 1 Nm Make test and valve setting according to description seeSteering test on page 43 Screw in the plastic plugs into the connect...

Page 42: ...p to 210 bar pressure for relief valve setting and steering test 3 l min and up to 280 bar pressure for shock valve setting The hydraulic oil must have a viscosity of 21 cSt at 50 C with a maximum degree of contamination according to ISO 4406 21 19 16 Set up OSPE with integrated priority valve 1 Connect double rod cylinder to L and R ports of OSPE 2 Connect pressure gauges to all ports of OSPE 3 C...

Page 43: ...ly and signal input for the PVE 6 Connect an external priority valve between P of pump station and P of OSPE Use Danfoss priority valve OLS 80 code 152B8269 or other OLS 80 with same orifice and spring specification Dynamic orifice Ø1 0 mm LS orifice Ø1 2 mm Spring 7 bar 7 Connect LS port of OSPE with LS port of OLS 8 Connect T port of OSPE to tank 9 Screw the adjusting screws of shock valves to b...

Page 44: ...he left observed by the cylinder movement For OSPED the number of turns on the steering wheel for moving the steering cylinder from lock to lock must increase in comparison to do this test with normal pump supply Without pump supply the number of turns must match cylinder volume emergency steer displacement of OSPED Example Cylinder volume 600 ccm and OSPED 60 185 LSRM Number of turns must be 600 ...

Page 45: ...ting of the former items the steering column wheel and port connections are removed P L R EF and LS ports are to be plugged and oil pressure of 20 bar is supplied to the T port for approx 3 minutes No leakage must be found in any assemblies or at the input shaft for the steering column Service Manual OSPE Steering Valve Test and valve setting of OSPE L1506577 Rev 0001 August 2015 45 ...

Page 46: ...s Maximum tightening torque Nm lbf in With cutting edge With copper washer With alum Washer O ring M12 1 5 30 265 20 177 30 265 25 221 M18 1 5 80 708 55 486 70 619 50 442 M22 1 5 100 885 65 575 80 708 60 531 Service Manual OSPE Steering Valve Tightening Torques 46 L1506577 Rev 0001 August 2015 ...

Page 47: ...Service Manual OSPE Steering Valve L1506577 Rev 0001 August 2015 47 ...

Page 48: ... Nordborg Denmark Phone 45 7488 2222 Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Danfoss Power Solutions Trading Shanghai Co Ltd Building 22 No 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...

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