Danfoss PVG 100 Service Manual
Proportional valves
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Also See for PVG 100:
- Technical information (76 pages) ,
- Service and parts manual (44 pages) ,
- Installation manual (12 pages)
Related Manuals for Danfoss PVG 100
Summary of Contents for Danfoss PVG 100
- Page 1 MAKING MODERN LIVING POSSIBLE Service Manual PVG 100 Proportional Valves powersolutions.danfoss.com...
- Page 2 Service Manual PVG 100 Proportional Valves Revision history Table of revisions Date Changed October 2014 Danfoss layout June 2009 First edition 11048807 • Rev BA • October 2014...
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Page 3: Table Of Contents
Personal safety..................................... 6 Hazardous material..................................6 Acronyms ......................................7 Operation PVG 100 Group with Open Center PVPF..........................8 PVG 100 Group with Closed Center PVPV..........................8 PVG 100 Sectional Drawing................................9 PVPC Plug for External Pilot Oil Supply..........................10 PVPC with Check Valve for Open Center PVP.........................10 PVPC without Check Valve for Open Center PVP......................10... - Page 4 Service Manual PVG 100 Proportional Valves Contents PVB Pilot Check Valve .................................. 35 PVEH, PVES, Electrical Actuators............................... 36 Troubleshooting Considerations............................36 PVEO On/Off Electrical Actuator...............................37 PVPC Plug for External Pilot Control..........................38 PVMR Friction Module................................39 11048807 • Rev BA • October 2014...
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Page 5: Overview
Introduction Overview This manual includes information for servicing PVG 100 valves. It includes a description of the units and their 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. -
Page 6: Safety Precautions
Service Manual PVG 100 Proportional Valves Introduction For repair, place the unit in a stable position with the shaft pointing downward. Secure the motor while removing and torquing controls, and valves.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. -
Page 7: Acronyms
Service Manual PVG 100 Proportional Valves Introduction Acronyms This table provides a definition of commonly used terms. P = Proportional V = Valve PVP/PVPF Pump side module, Open center PVPV Pump side module, Closed center Basic module PVLA Anti-cavitation valve... -
Page 8: Operation
PVG 100 Proportional Valves Operation PVG 100 Group with Open Center PVPF When the pump is started and the main spools in the individual basic modules are in the neutral position, oil flows from the pump, through connection P, across the pressure matching spool to tank. The oil flow led across the pressure matching spool determines the pump pressure (stand-by pressure). -
Page 9: Pvg 100 Sectional Drawing
Service Manual PVG 100 Proportional Valves Operation PVG 100 Sectional Drawing Logic cartridge for POC LS relief valve Pressure compensator LS connection 10. Shock and suction valve, PVLP Priority spool for CF 11. Main spool, PVBS LS connection for steering unit 12. -
Page 10: Pvpc Plug For External Pilot Oil Supply
PVPC with Check Valve for Open Center PVP PVPC, with check valve, is used in systems where it is necessary to operate the PVG 100 valve by means of the electrical remote control without pump flow. When the external solenoid valve is opened, oil from the pressure side of the cylinder is fed via the PVPC through the pressure reducing valve to act as the pilot supply for the electrical actuators. -
Page 11: Friction Detent
Service Manual PVG 100 Proportional Valves Operation 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. -
Page 12: Pvbs, Main Spools For Flow Control (Standard)
The coil on the valve must be energized for pilot oil to be available in the valve stack. This safety feature vents all hydraulic controls dependant on the PVG 100 pilot supply to the TØ gallery, thus reducing the possibility of accidental activation of a hydraulic work function. -
Page 13: Pvpe Electrical Full Flow Unloading Valve
Service Manual PVG 100 Proportional Valves Operation PVPE Electrical Full Flow Unloading Valve 350 bar Max. operation pressure [5085 psi] 1.2 bar Max. pressure drop a an flow of 0.20 l/min. [0.053 US gal/min] [17 psi] 30 to 60°C Recommended temperature [86 to 140°F]... -
Page 14: System Troubleshooting
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 100 Technical Information Manual 520L0720 for valve configuration information. Refer to PVG 100 Parts Manual 520L0888 for part numbers. - Page 15 Service Manual PVG 100 Proportional Valves System Troubleshooting Our service manuals give full guidance on use of special tools. Troubleshooting flow chart Problem? Problem? Problem? Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Electrical...
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Page 16: No Cylinder/Motor Response In Either Direction When Remote Controller Is Actuated
Excessive internal leakage may overheat the Install loop flushing defeat option and monitor system. case flow. If case flow is excessive, motor may require major repair. Contact Danfoss Service. Shock valves Swap and see if problem follows Replace valves Solenoid actuation... -
Page 17: Main Valve Spool Moves Without Oil Passing To Cylinder/Motor
Service Manual PVG 100 Proportional Valves System Troubleshooting 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 Repair or replace pump per manufacturers procedure Optional pressure compensator in valve section... -
Page 18: Cylinder/Motor Responds Slowly To Remote Electrical Or Hydraulic Controller
Service Manual PVG 100 Proportional Valves System Troubleshooting Cause Check Corrective action Contamination in the hydraulic oil Take oil samples to confirm Flush hydraulic system. Fill with clean filtered oil. Cylinder/Motor Responds Slowly to Remote Electrical or Hydraulic Controller Cause... -
Page 19: Electrical Supply
Service Manual PVG 100 Proportional Valves System Troubleshooting Cause Check Corrective action 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 Repair or replace relief valve... -
Page 20: Hydraulic (Remote) Pilot Control Pressure
Service Manual PVG 100 Proportional Valves System Troubleshooting Cause Check Corrective action Main spool position feedback transducer signal Test oil for contamination and or water content If oil contamination is too high, flush hydraulic incorrect system or replace oil if necessary. If problem... -
Page 21: Pvg 100 Component Troubleshooting
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting Open Center Pressure Relief Valve Description: Adjustable relief valve. Adjustment range 50 Bar [700 PSI] to 350 Bar [5000 PSI]. Location: The relief is in all PVP Inlet modules Function: Pilots the unloading valve to open when the load exceeda a set pressure. - Page 22 Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting Failure mode Cause Corrective action Main spools are slow, driven by PVE 13 Bar [190 Contamination Disassemble and clean PSI] pilot system Pump pressure too low - below 9 Bar [130 PSI]...
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Page 23: Pressure Gauge Connection
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting 13 mm 85 Nm [750 lbf•in] P107 921E Pressure Gauge Connection Description: Port to install a pressure gauge to check pressure relief valve setting to valve specification. Location: On inlet cover to valve stack. -
Page 24: Pressure Matching Spool
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting Check valve PVPC with check valve P107 958E Pressure Matching Spool Description: Main pump flow unloading spool. Location: PVP (inlet) module. Function: Unloading spool.Serviceability: All internal components can be removed from the cavity,... -
Page 25: Ls Signal
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting 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. -
Page 26: Shuttle Valve
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting 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 LS passages blocked or restricted Disassemble valve. -
Page 27: Main Spool
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting Failure mode Cause Corrective action Valve sections will not build pressure Worn shuttle disc Replace complete module (seat is pressed into module) Normally it will be one section, but not all... - Page 28 Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting Serviceability: Main spool is serviceable depending on failure mode. 1. Remove manual actuator (not shown) using a 5 mm internal hex wrench to remove the four mounting screws. Pull the spool out of the valve body.
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Page 29: Shock And Anti-Cavitation Valve Pvlp
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting Main spool Friction detent 8 Nm [70 lbf·in] 11 mm 8 Nm Mechanical [70 lbf·in] float 8 Nm [70 lbf·in] . 5 m Detent 8 Nm [70 lbf·in] Main spool 8 Nm [70 lbf·in]... -
Page 30: Pressure Compensator
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting 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... -
Page 31: Maximum Oil Flow Adjustment Screws For Ports A And B
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting 27 mm 60 Nm [44 lbf•ft] Pressure compensator spool P107 843 Maximum Oil Flow Adjustment Screws for Ports A and B Description: Optional mechanical flow limiter. Location: PVM manual control handle. -
Page 32: Pvm Module
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting Adjusting screws for ports A and B For standard mount, top adjusting screw is B and bottom adjusting screw is A PVM Module Description: Manual control lever. Location: Mounted on either end of the PVB main spool. -
Page 33: Pvt/Pvti Module
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting PVM module O-rings Seal Screw (x4) 5 mm 8 Nm [70 lbf•in] P107 848 PVT/PVTI Module Description: End cover. Location: Mounted on the last PVT of the valve stack. Function: Serves as blanking cover and drain for LS circuit. -
Page 34: Pvas Module
PVLA 13 mm P107 849 40 Nm [354 lbf•in] For specifications and operating parameters on PVG 100 valves, refer to PVG 100 Technical Information Manual 520L0720. PVAS Module Description: Tie rod kit. Location: Through the valve stack. Function: Holds the stack together. -
Page 35: Pvpp Pilot Shut Off Valve
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting 10 mm 17 mm 38-42 Nm 38-42 Nm [28-31 lbf•ft ] [28-31 lbf•ft ] Nut for PVTI Nut for PVT PVTI P107 850 PVPP Pilot Shut Off Valve Description: Optional two way position solenoid normally closed... -
Page 36: Pveh, Pves, Electrical Actuators
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting Location: In the PVB Function: Low leakage on the work ports Failure mode Cause Corrective action Internal leakage Component wear Replace module Contamination Replace module PVEH, PVES, Electrical Actuators Description: Proportional electrical actuator. -
Page 37: Pveo On/Off Electrical Actuator
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting Failure mode Cause Corrective action Works in one direction (Assuming that the No control voltage from the electrical controller Ensure voltage from the electrical controller manual control lever and the main spool move... -
Page 38: Pvpc Plug For External Pilot Control
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting 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... -
Page 39: Pvmr Friction Module
Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting PVPC plug for external pilot Check valve P107 958E PVMR Friction Module Description: Mechanical friction hold. Location: Mounted on main spool in the PVB. Function: Infinite mechanical positioning of the main spool. - Page 40 Service Manual PVG 100 Proportional Valves PVG 100 Component Troubleshooting PVMR module Plug 36 mm 15 Nm [133 lbf•in] Plug (x3) 11 mm Mechanical detent 4 Nm [35 lbf•in] Screw (x4) 5 mm 8 Nm [71 lbf•in] P107 811E 11048807 • Rev BA • October 2014...
- Page 41 Service Manual PVG 100 Proportional Valves 11048807 • Rev BA • October 2014...
- Page 42 Service Manual PVG 100 Proportional Valves 11048807 • Rev BA • October 2014...
- Page 43 Service Manual PVG 100 Proportional Valves 11048807 • Rev BA • October 2014...
- Page 44 Phone: +86 21 3418 5200 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed.