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Danfoss PVG 120, Service Manual

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PVP, pump side module

Code number

O-ring
Boss

SAE
flange

Metric flange

Weight
kg [lb]

Open
centre

Excl. PVPD, PVPH, PVPE

155G5023

155G5037

155G5021

10.0 [22.1]

For PVB-oil flow > 180 l/min [47.6
US gal/min]
Excl. PVPD, PVPH, PVPE

155G5028

155G5029

155G5027

Closed
centre

Incl. pressure relief valve and plug
PVPD

155G5022

155G5038

155G5020

10.2 [22.5]

Excl. pressure relief valve

155G5031

155G5032

155G5030

11.0 [24.3]

Accessory modules for open centre PVP

Description

Code number

Weight
kg [lb]

Plug, PVPD

155G5041

0.4 [0.9]

Hydraulic relief valve, PVH

155G5061

0.5 [1.1]

Electrical relief valve, PVPE

12 V

155G5052

0.7 [1.5]

24 V

155G5054

PVH, cover for PVRHH

Port

Code number

Weight, kg [lb]

1/2 in - 20 UNF

155G4021

0.4 [0.9]

G 1/4

155G4022

PVE, electrical actuation

Connector

PVEH fault monitoring

PVEO voltage

Active

Passive

12 V

24 V

Hirschmann

155G4092

155G4093

155G4272

155G4274

AMP

155G4094

155G4095

155G4282

155G4284

Weight, kg [lb]

1.25 [2.76]

1 [2.2]

PVLA suction valve A/B

Code number

Weight
kg [lb]

155G1065

0.2 [0.4]

PVLP, shock and suction valve A/B

Pressure setting

bar

[psi]

Code number

50

725

155G0050

75

1100

155G0075

100

1450

155G0100

125

1800

155G0125

150

2200

155G0150

Service Manual

PVG 120 Proportional Valve Group

PVG 120 Modules Selection Chart

46

520L0247 • Rev JA • May 2014

Summary of Contents for PVG 120

Page 1: ...MAKING MODERN LIVING POSSIBLE Service Manual Proportional Valve Group PVG 120 powersolutions danfoss com ...

Page 2: ...ted to Danfoss layout DITA CMS major revision JA Jan 2012 Pos 3 change ID Feb 2011 Table on page 35 changed layout changes all pages IC Feb 2010 Handles on drawings IA Jan 2010 Japan location HC Service Manual PVG 120 Proportional Valve Group 2 520L0247 Rev JA May 2014 ...

Page 3: ...VPE technical data 21 Connection PVPE 22 PVP PVP Pump Side Module 23 PVPD PVPH PVPE Accessories for PVP 25 PVLP PVLA PVLP PVLA Shock and Suction Valve Port A B 27 PVBP PVBR PVBC PVBU PVBP PVBR PVBC PVBU Accessories for PVB 29 PVM PVM Mechanical Activating Module 31 PVMD and PVH PVMD Cover for PVM and PVH Hydraulic Activation 33 PVGI PVGI Interface for PVG 120 and PVG 32 34 PVEH and PVEO PVEH and P...

Page 4: ...Ordering of modules for oil flow exceeding 180 l min 47 6 US gal min 48 Order Form 48 Reordering 49 Service Manual PVG 120 Proportional Valve Group Contents 4 520L0247 Rev JA May 2014 ...

Page 5: ...20 service parts exploded view 13 8 7 2 3 3 3 3 11 14 12 4 5 4 14 1 9 10 5 5 5 6 V310144 A 6 6 6 Service Manual PVG 120 Proportional Valve Group PVG 120 service parts exploded view 520L0247 Rev JA May 2014 5 ...

Page 6: ... 3 Shuttle valve 4 Pressure relief valve in PVP 5 Pressure compensator in PVB 6 LS pressure relief valve in PVB 7 Shock and suction valve PVLP 8 Suction valve PVLA 9 Orifice closed center PVP Plug open center PVP 10 LS connection 11 Orifice open center PVP 12 Plug closed center PVP Service Manual PVG 120 Proportional Valve Group PVG 120 sectional view 6 520L0247 Rev JA May 2014 ...

Page 7: ...tool used in new applications as it will indicate whether there are special safety considerations to be met according to the machine directives EN 13849 Dependent on the determined levels conformity this analysis will detirmine if any extra requirements for the product design development process production process or maintenance i e the complete product life cycle W Warning All makes brands and ty...

Page 8: ... ensure the PLUS 1 main controllers correct function of the manlift Legend 1 Main power supply 2 Emergency stop man present switch 3 HMI Joystick control 4 Movement detection sensors 5 Main controller 6 PVG control valve 7 Hydraulic deactivation Service Manual PVG 120 Proportional Valve Group Safety in application 8 520L0247 Rev JA May 2014 ...

Page 9: ...lacement pumps PVSK commonly used in crane application full flow dump PVPX LS dump to tank PVG 100 alternative LS dump or pilot supply disconnect PVPP pilot oil supply shut off External cartridge valve connecting LS pressure or main pressure to tank PVG 120 pump disconnect block for variable pumps PVPE full flow dump for the PVG 120 External cartridge valve connecting LS pressure to tank Service M...

Page 10: ...Supply control signal neutral OFF Delay 1 PVE 1 PVE 2 Emergency stop Man present switch C C D B B A P301 318 A Emergency stop man present switch B PVE Fault monitoring signals C Neutral signal detection D Hydraulic deactivation System Control Logic e g PLUS 1 for signal monitoring and triggering signal for deactivation of the hydraulic system W Warning It is the responsibility of the equipment man...

Page 11: ... Delay DI Logic Memory US DI A DI B 2 4 3 Output Fault detection Delay DI Logic Memory US DI A DI B 2 4 3 Output OR Emergency Stop Man present switch P301 319 UDC2 Error US DI B Error DI A UDC2 Error US Error DI A Hydraulic deactivation System Control Logic e g PLUS 1 for signal monitoring and triggering signal for deactivation of the hydraulic system W Warning It is the responsibility of the equi...

Page 12: ... week and year of installation D PVP pressure setting E PVP number week year and day manufacturing issue and series No F PVB A Port number week year and day manufacturing issue and series No G PVT week and year of manufacturing Service Manual PVG 120 Proportional Valve Group Identification 12 520L0247 Rev JA May 2014 ...

Page 13: ...48 100 3 94 105 4 13 L 4xM12x18 4x7 16 14UNCx0 7 V310179 A Room for dismantling Module of PVB 1 2 3 4 5 6 7 8 L mm 168 235 302 369 436 503 570 637 L in 6 61 9 25 11 88 14 53 17 17 19 80 22 44 25 08 Connection PVP Pump Side Module Service Manual PVG 120 Proportional Valve Group Installation 520L0247 Rev JA May 2014 13 ...

Page 14: ...ghtening torques Ports PA PB MA LS LX PP Sealing thread G 1 4 G 1 4 G 3 8 With steel washer 35 N m 310 lbf in 40 N m 350 lbf in 60 N m 530 lbf in With cooper washer 30 N m 270 lbf in 20 N m 180 lbf in 35 N m 310 lbf in With aluminium washer 30 N m 270 lbf in 30 N m 270 lbf in 40 N m 350 lbf in With cutting edge 35 N m 310 lbf in 40 N m 350 lbf in 60 N m 530 lbf in Service Manual PVG 120 Proportion...

Page 15: ...ep 400 lbf in Max tightening torques UN and UNF Connection Threads O ring Boss Port Max tightening torques Ports P A B T PA PB MA LS LX PP Sealing Thread 1 5 16 in 12 UN 1 1 16 in 12 UN 1 5 16 in 12 UN in 20 UNF in 20 UNF in 20 UNF O ring 160 N m 120 N m 160 N m 30 N m 30 N m 60 N m 1410 in lbs 1060 in lbs 1410 in lbs 270 in lbs 270 in lbs 530 in lbs Ports identification Service Manual PVG 120 Pro...

Page 16: ...87 5 1 9 5 19 5 V310018 A 22 5 52 5 82 5 1 1 2 5 1 4 2 5 172 5 19 5 19 5 V310014 A Setting of max flow Setting of Max Flow 10 0 39 8 Nm B A max B 70 lbf in LX T PP 3 0 12 Q Q max A max Q max Q max B Q max A Q V310101 A Service Manual PVG 120 Proportional Valve Group Installation 16 520L0247 Rev JA May 2014 ...

Page 17: ...bf in 3 Nm 27 lbf in P MA LS 6 0 24 6 0 24 3 0 12 3 0 12 V310102 A PVB LS Relief Valve Pressure Setting PVB LS Relief Valve Setting 360 130 bar 360 1900 psi 3 Nm 27 lbf in LX T PP 3 0 12 6 24 8 0 31 3 0 12 6 24 3 0 12 510 lbf in 35 Nm V310094 A Service Manual PVG 120 Proportional Valve Group Installation 520L0247 Rev JA May 2014 17 ...

Page 18: ...n of PVE For security reasons any replacement of O rings between valve block 1 and intermediate plate 2 may only be effected at service shops authorized by Danfoss C Caution Mixing up PVE series 2 for PVG 120 may lead to self actuation Service Manual PVG 120 Proportional Valve Group Installation 18 520L0247 Rev JA May 2014 ...

Page 19: ...PVEH PVEO Service Manual PVG 120 Proportional Valve Group Installation 520L0247 Rev JA May 2014 19 ...

Page 20: ...H relief valves Max tightening torque for PVPE PVH Position Across flats Max tightening torque 1 22 mm 0 87 in 5 N m 45 lbf in 2 36 mm 1 42 in 85 N m 750 lbf in 3 36 mm 1 42 in 85 N m 750 lbf in Tightening PVPE PVH S MA P 2 5 0 098 2 Nm 17 5 lbf in L PVP PVPH 2 LS LS V310157 A 1 PVPE Service Manual PVG 120 Proportional Valve Group Installation 20 520L0247 Rev JA May 2014 ...

Page 21: ...ture Recommended temperature 30 to 60 C 86 to 140 F Min temperature 30 C 22 F Max temperature 90 C 194 F Max coil surface temperature 155 C 311 F Ambient temperature 30 to 60 C 22 to 140 F Oil viscosity Operating range 12 to 75 mm s 65 to 347 SUS Min viscosity 4 mm s 39 SUS Max viscosity 460 mm s 2128 SUS Response time for pressure relief to tank 600 ms Enclosure to IEC 529 IP 65 Rated voltage 12 ...

Page 22: ...nnection PVPE Installing the wire When installing the wire remember to connect the built in diode to the plug pins Service Manual PVG 120 Proportional Valve Group Installation 22 520L0247 Rev JA May 2014 ...

Page 23: ...PVP Pump Side Module Service Manual PVG 120 Proportional Valve Group PVP 520L0247 Rev JA May 2014 23 ...

Page 24: ...2 0 02 in 155G5318 1 1 1 Screw M5 0 2 in 681X3019 1 1 1 22 Spool 155G5312 1 1 1 1 1 1 155G5321 1 1 1 23 Plug 070 2741 1 1 1 1 1 1 1 1 1 24 Bonded seal 10 35 2 0 0 41 0 08 in 633B9016 1 1 1 1 1 1 1 1 1 25 Pin 1 1 1 1 1 1 1 1 1 26 Name plate 155A5021 1 1 1 1 1 1 1 1 1 1 1 1 27 Drive srew 681Z8055 2 2 2 2 2 2 2 2 2 2 2 2 28 Plastic plug 633X1028 1 1 1 1 1 1 1 1 633X0064 1 1 1 1 Set of seals 155G8501 ...

Page 25: ...PVPD PVPH PVPE Accessories for PVP Service Manual PVG 120 Proportional Valve Group PVP 520L0247 Rev JA May 2014 25 ...

Page 26: ...0 08 in 633B0068 1 1 5 O ring 26 7 1 78 1 05 0 07 in 633B0070 1 1 6 Spring 155G5332 1 1 7 0 5 0 2 0 02 in 155G5318 2 2 2 8 Spool 155G5311 1 1 1 9 Plug 631X2040 1 10 O ring 30 3 2 4 1 18 0 09 in 633B1441 1 1 11 Insert incl item 9 10 155G5041 1 12 Plastic plug 633X7018 13 Nut 155G5404 2 14 Bushing 155G5403 1 15 Back up ring 155G2316 1 16 O ring 25 3 2 4 1 0 0 09 in 633B1440 1 17 Spool 155G5405 1 18 ...

Page 27: ...PVLP PVLA Shock and Suction Valve Port A B Service Manual PVG 120 Proportional Valve Group PVLP PVLA 520L0247 Rev JA May 2014 27 ...

Page 28: ...PVLP 250 bar 3625 psi 155G0251 1 PVLP 275 bar 3988 psi 155G0276 1 PVLP 300 bar 4351 psi 155G0301 1 PVLP 325 bar 4713 psi 155G0326 1 PVLP 350 bar 5076 psi 155G0351 1 PVLP 375 bar 5438 psi 155G0376 1 PVLP 400 bar 5801 psi 155G0401 1 19 Plastic plug to protect cartridge 633X0053 1 20 Spring 155G1387 1 1 21 PVLA 155G1066 1 Set of seals 155G8525 1 1 Type Code No PVLP pressure setting 50 75 100 125 175 ...

Page 29: ...PVBP PVBR PVBC PVBU Accessories for PVB Service Manual PVG 120 Proportional Valve Group PVBP PVBR PVBC PVBU 520L0247 Rev JA May 2014 29 ...

Page 30: ...stment disc 155G2315 4 4 4 4 10 Spring 155G2317 1 1 1 11 Plug 155G2322 1 12 Plug 631X2036 1 1 13 Bonded seal 14 7 1 5 0 58 0 06 in 633B9017 1 14 Plug 155G2323 1 15 Spring 155G2324 1 16 Plug 155G2319 1 17 Washer 13 5 17 5 1 5 0 53 0 69 0 06 in 684X2120 1 Set of seals 155G8502 1 1 1 1 Type Code No PVBU uprating kit for PVB 155G6035 PVBR LSA B relief valve 155G6080 PVBP plug 155G6081 PVBC connection ...

Page 31: ... lbf in 8 0 5 Nm 4 7 6 5 8 1Nm 70 9 lbf in 5 0 20 8 1 Nm 70 9 lbf in PVM 10 0 39 6 mm 13 mm 22 9 lbf in 2 5 1 Nm 3 0 12 3 1 V310171 A 71 9 lbf in 8 1 Nm 8 1 Nm 70 9 lbf in 0 24 in 0 51 in 4 mm 0 12 in 14 2 Service Manual PVG 120 Proportional Valve Group PVM 520L0247 Rev JA May 2014 31 ...

Page 32: ...B1005 1 1 10 Spool control pin 155G3313 1 1 11 Stop 155G3314 1 1 12 Spring 155G3317 1 155G3318 1 13 Stop 155G3315 1 1 Type Code No PVM with PVMD or PVE 22 5 37 5 155G3040 PVM with PVH 22 5 37 5 155G3050 Spare Part Kits Available Item Description Code no 14 Lever with black knob handle and base 11046724 Set of seals 155G8518 Lever with red knob handle and base 11064640 1 Handle black knob including...

Page 33: ...on Code No 17 Screw M6 25 0 80 0 07 in 681X1198 4 4 4 18 Plastic plug 633X7018 2 633X0018 2 19 Cover 155G4301 1 155G4201 1 20 O ring 6 0 2 0 0 24 0 78 in 633B1460 4 4 4 21 O ring 27 0 2 0 1 06 0 78 in 633B0407 1 1 1 22 Cover 155G4402 1 Set of seals 155G8505 1 1 1 Service Manual PVG 120 Proportional Valve Group PVMD and PVH 520L0247 Rev JA May 2014 33 ...

Page 34: ... 1 1 2 O ring 24 0 2 0 0 94 0 08 in 633B1428 1 1 1 3 O ring 10 0 2 0 0 39 0 08 in 633B1461 2 2 2 4 Bonded seal 14 7 1 5 0 58 0 06 in 633B9017 1 1 1 5 Plug G 1 4 631X2036 1 1 2 20 UNF 155L6405 1 1 6 Plug 631X2040 3 3 3 7 O ring 30 3 2 4 1 19 0 08 in 633B1441 3 3 3 8 Plastic plug 633X1028 1 1 633X0019 1 Service Manual PVG 120 Proportional Valve Group PVGI 34 520L0247 Rev JA May 2014 ...

Page 35: ...PVEH and PVEO Electrical Activating Module ON OFF Service Manual PVG 120 Proportional Valve Group PVEH and PVEO 520L0247 Rev JA May 2014 35 ...

Page 36: ...in 633B1148 1 1 1 1 1 1 1 1 6 O ring 15 2 0 59 0 78 in 633B1030 1 1 1 1 1 1 1 1 7 O ring 10 2 0 39 0 78 in 633B1267 2 2 2 2 2 2 2 2 8 O ring 27 2 1 06 0 78 in 633B0407 1 1 1 1 1 1 1 1 Set of seals 155G8519 1 1 1 1 1 1 1 1 Type Connector Code No PVEH Fault monitoring active 11 32V Hirschman 155G4092 AMP 155G4094 Fault monitoring passive 11 32V Hirschman 155G4093 AMP 155G4095 PVEO 12V Hirschman 155G...

Page 37: ...PVT Tank Side Module Upper Part Service Manual PVG 120 Proportional Valve Group PVT 520L0247 Rev JA May 2014 37 ...

Page 38: ...0 22 0 04 in 633B9029 1 1 1 5 Plug item 3 and 4 155G8555 6 O ring 10 0 x 2 0 0 39 0 08 in 633B1461 2 2 2 2 2 2 7 O ring 24 0 x 2 0 0 94 0 08 in 633B1428 1 1 1 1 1 1 8 Plastic plug 633X1028 1 1 1 1 633X0064 1 1 9 Tank part assy 1 1 1 1 1 1 Set of seals 155G8507 1 1 1 1 1 1 Used only when load signal is carried to LX port 155G8555 1 1 1 1 1 1 Without LX connection Code No PVT SAE UNF mounting thread...

Page 39: ...PVT Tank Side Module Lower Part Service Manual PVG 120 Proportional Valve Group PVT 520L0247 Rev JA May 2014 39 ...

Page 40: ... 1 20 Spool 155G7374 1 1 21 Plug 155L1373 1 1 22 O ring 16 0 x 1 5 0 63 0 06 in 633B1813 1 1 23 Stop 155G7382 1 1 24 Washer 7 4 x 11 5 x 1 0 0 29 0 45 0 04 in 684X2547 2 2 25 Spring 155G7381 1 1 26 Ball 689X1040 1 1 Set of seals 155G8524 1 1 Kit for hydraulic activation 155G7041 1 1 UNC Code No PVT with pilot supply for PVE 155G7042 PVT without pilot supply for PVE 155G7062 BSP F thread Code No PV...

Page 41: ...t seal and nut on long thread and torque 10 N m 5 When all three stay bolts are mounted torque full to 80 N m W Warning Do not reuse stay bolts or loosen torque The stay bolts are not designed as motor bolts and do not keep strength when remounted Service Manual PVG 120 Proportional Valve Group PVAS and PVGI 520L0247 Rev JA May 2014 41 ...

Page 42: ... 0 47 l 328 5 12 93 in PVGI 155G8333 3 Stay bolt M12 0 47 l 396 5 15 61 in PVGI 155G8334 3 4 4 Pin 682L2006 18 16 14 12 10 8 6 4 10 8 6 4 2 5 5 O ring 33 3 x 2 4 1 31 0 09 in 633B1029 18 16 14 12 10 8 6 4 10 8 6 4 2 6 6 O ring 28 24 x 2 62 1 118 0 10 in 633B1956 9 8 7 6 5 4 3 2 5 4 3 2 1 7 7 O ring 11 91 x 2 62 0 47 0 10 in 633B1955 18 16 14 12 10 8 6 4 10 8 6 4 2 8 O ring 5 0 x 2 0 0 20 0 08 in 6...

Page 43: ... 69 0 09 in 633B1335 1 16 O ring 24 0 x 2 0 0 94 0 08 in 633B1428 1 17 O ring 25 3 x 2 4 1 00 0 09 in 633B1440 1 1 18 O ring 30 3 x 2 4 1 19 0 09 in 633B1441 1 2 1 19 O ring 6 0 x 2 0 0 24 0 08 in 633B1460 4 1 20 O ring 10 0 x 2 0 0 39 0 08 in 633B1461 2 21 O ring 13 3 x 2 4 0 52 0 09 in 633B1462 1 1 22 O ring 20 3 x 2 4 0 78 0 09 in 633B1521 1 23 O ring 16 0 x 1 5 0 63 0 06 in 633B1813 1 24 O rin...

Page 44: ...Boss Metric flange Weight kg lb Facilities for shock valves AB 155G6007 155G6006 155G6005 10 2 22 5 PVB low basic module SAE flange O ring Boss Metric flange Weight kg lb No facilities for shock valves AB 155G6016 155G6015 155G6014 8 9 19 6 Service Manual PVG 120 Proportional Valve Group PVG 120 Modules Selection Chart 44 520L0247 Rev JA May 2014 ...

Page 45: ... PVE 155G3040 155G3041 22 5 37 5 PVM PVH 155G3050 155G3051 22 5 37 5 Weight kg lb 0 5 1 1 PVMD cover for PVM Code number Weight kg lb 155G4061 0 3 0 7 PVT tank side module Code number SAE flange O ring Boss Metric flange Weight kg lb Upper part excl LX connection 155G7022 155G7021 155G7020 4 6 10 1 Upper part incl LX connection 155G7025 155G7024 155G7023 Lower part incl pilot oil supply for PVE 15...

Page 46: ... PVH 155G5061 0 5 1 1 Electrical relief valve PVPE 12 V 155G5052 0 7 1 5 24 V 155G5054 PVH cover for PVRHH Port Code number Weight kg lb 1 2 in 20 UNF 155G4021 0 4 0 9 G 1 4 155G4022 PVE electrical actuation Connector PVEH fault monitoring PVEO voltage Active Passive 12 V 24 V Hirschmann 155G4092 155G4093 155G4272 155G4274 AMP 155G4094 155G4095 155G4282 155G4284 Weight kg lb 1 25 2 76 1 2 2 PVLA s...

Page 47: ...350 5100 155G0350 375 5400 155G0375 400 5800 155G0400 Weight kg lb 0 175 0 386 PVAS assembly kit PVB s 1 2 3 4 5 6 7 8 Code number 155G8031 155G8032 155G8033 155G8034 155G8035 155G8036 155G8037 155G8038 Weight kg 0 8 1 0 1 1 1 2 1 4 1 7 1 9 2 1 lb 1 8 2 2 2 4 2 6 3 1 3 7 4 2 4 6 Service Manual PVG 120 Proportional Valve Group PVG 120 Modules Selection Chart 520L0247 Rev JA May 2014 47 ...

Page 48: ...ement 1 Ordering Order accessory module 155G6035 and main spool D 2 Conversion In closed center systems a max oil flow exceeding 180 l min 47 6 US gal min can be achieved by changing the following basic module parts The spring behind the pressure compensator The plug behind the pressure compensator The code number of the spring and plug is 155G6035 PVBU accessory module Order Form An order form fo...

Page 49: ...foss to fill in The code number for the whole of the specified valve group PVG No is entered here In the event of a repeat order all you have to do is enter the number Danfoss has given on the initial confirmation of order If PVG 120 is to be used with phosphate esters this must be stated on the order form See Non flammable Fluids for more information Service Manual PVG 120 Proportional Valve Grou...

Page 50: ...Service Manual PVG 120 Proportional Valve Group Order specification 50 520L0247 Rev JA May 2014 ...

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