OSPE Steering Valve Service Manual
Contents
1. OSP 9 L p R Jil UNIF Se WA lento sl Man arn D talge Li O ki ke A ATT ATP J E L Y alos i Rr Lr P E sii AS ERTA kee F 1 Electronics H AAAA d R F k 1 Ge 9 1 X j li whe ET L GE d i CT E o EN SS bebes A G i gt ES ail A VW TE i gt K A a ees Lilo A A MAS SE AE Il TS Li is EE PEPA P EF T L R P301 171 Set up for testing A universal hydraulic work bench is required for this setup The work bench must support the following pump capacity e AS min and up to 210 bar pressure for relief valve setting and steering test e 31 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 Connect steering column and steering wheel to the input shaft of the OSPE 42 L1506577 Rev 0001 e August 2015 Davis Service Manual OSPE Steering Valve Test and valve setting of OSPE 4 ON AO UI Set bb W N If OSPE2. Dismantling Dismantling OSPE continued Screw out the seats for shock valves 63 using a 2 75 mm Hex key O ring 41 is fitted on seat 63 Screw out the plug 205 using a 32 mm O socket spanner 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 F302 095 F302 096 F302 097 F302 098 Replace the unit in the holding tool on steering column A end 16 11506577 Rev 0001 August 2015 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued Remove the plug 93 for the pilot relief 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 11506577 Rev 0001 e August 2015 F302 099 F302 101 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued Screw out the LS check valve 221 using a 3 mm Hex key This check valve is not present in all OSPE s 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 usinga 13mm O socket or ring spanner OSPE Has 7 identical screws 7x 31 Rem
3. Dismantling Dismantling OSPE continued Screw out the pin bolts 80 using a 4 mm O Hex key Screw out the plug 216 using a 6 mm 0 Hex key O ring 314 is fitted on plug 216 Remove plug 216 and spool 215 22 11506577 Rev 0001 e August 2015 F302 119 F302 120 F302 121 F302 122 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued Screw out the plug 225 using a 5 mm Hex key Remove spool 224 using a 4 mm screw Shake out the check valve ball 5 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 11506577 Rev 0001 August 2015 F302 123 F302 124 F302 125 F302 126 23 24 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued Press the spool 1 inwards from the steering column end and the sleeve 1 ring 16 neutral position springs 14 and bearing assembly 18 will be pushed 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 spoo
4. ooo CTC CAMS o p CUTE O EI ooo CTS gt fe OO ETT Od oms O ooo omose O o L1506577 Rev 0001 August 2015 Service Manual OSPE Steering Valve Exploded View and Seal Kit OSPE seal kit and spare parts Coil Deutsch DOS 12V DE 322113 11084688 E Coil AMP DO8 12V AJE 321930 11084690 Spare part bag containing 11085713 eN 248 249 Cartridge spool for pilot dump Nut and O ring Seal kit OSPE steering unit part 150N4041 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 Containing seal kits codes Seal kit KIT OSPE complete 11160838 150N4041 11160415 155L6870 157B4997 120433 L1506577 Rev 0001 August 2015 9 Service Manual OSPE Steering Valve Tools Tools for OSPE Tools Holding tool for the entire steering valve Material Appropriate metal or hard plastic This tool is not available from Danfoss P301 787 Assembly tool for dust seal Material Free cutting steel This tool is not available from Danfoss 26 0 1 min 040 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 o
5. 210 bar The steering wheel is actuated until the steering cylinder reaches one of its end strokes and the steering wheel is actuated in this cylinder position with steering torque 25 5 Nm The pilot relief valve item 95 of exploded view is set according to specification Maximum steering pressure P T bar for the code in question The setting pressure is the pressure on the P port minus the T port of OSPE Neutral positioning test OSP part After adjusting the pilot relief valve the steering wheel must be able to go to neutral position by itself no later than 1 second after the activation of the steering wheel has been stopped The steering unit is in neutral position when the pressure drop P T is no higher than 18 bar Neutral positioning test EH part Manual steering Shock valves 44 For OSPE with PVES PVED CC PVED CL Apply battery power to the coil item 247 on exploded view Apply battery power and input signal to the PVE observe that the steering cylinder is moving according to direction of input signal for PVE Apply neutral position signal for PVE observe that cylinder movement stops and that pressure LS T drops to max 10 bar For OSPE with PVED CLS The coil item 247 of exploded view is controlled by the PVED CLS Without pressure on P and T ports the unit must be able to steer in a smooth manner to the right and to the left observed by the cylinder movement For OSPED the number of turns on the ste
6. 243 using a 17 mm O socket spanner 45 5 Nm F302 169 40 11506577 Rev 0001 August 2015 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued Check proper movement of EH spool 202 press on spool end the spool must be able to be moved downwards 4 mm with force lt 100N and it must be able to return to starting position by help of the neutral spring package integrated in the spool end facing plug 205 Place O rings 320 321 322 and filter 323 on PVE 204 Place the 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 O socket spanner 5 1 Nm Screw in the plastic plugs into the connection ports to keep the ports clean during storage and transportation 11506577 Rev 0001 August 2015 F302 170 F302 080 F302 171 F302 172 41 Davis Service Manual OSPE Steering Valve Test and valve setting of OSPE This section describes minimum tests needed when the OSPE steering valve has been disassembled and reassembled OSPEDC LSRM with integrated priority valve
7. MAKING MODERN LIVING POSSIBLE Service Manual Steering Valve OSPE powersolutions danfoss com Service Manual OSPE Steering Valve Revision history Table of revisions August 2015 Codenumber changed 0001 11506577 Rev 0001 August 2015 Service Manual OSPE Steering Valve Contents Safety Precautions Sue E aorta 4 Service Literature Symbols Used lafe E lui te HEEL TTC 5 Ee We EE 5 Exploded View and Seal Kit OSPE GOCE L VIEW rico E A E AA A TEE E 6 PEDIS E EE 7 Tools TOO TOROS E rei 10 Dismantling DIM UI te PE ass 12 Assembly ASSIM OSPE ss aerea 26 Test and valve setting of OSPE js o A e E A E A ed Ata en aunt earns 42 Set up OSPE with integrated priority ValVe sssssssssssesssessesssecsssssecsssssssssssssssssscsssesssssssesssessesssesassesesssseescsesecsssesseees 42 Set up OSPE without integrated priority VAIVE cssscsssssssssecsssessssssscsssssecsssessssssscscsssscsesesssseescsssesscssseeasseescseseeseeeees 43 o o o 5 o o O ee ee er eee 43 lO E E Y AP E O O OO OI ater ois ae ae eae ea annie 44 Neutral POSITIONING test OSP o E 44 Neutral positioning test EH Part socsscesasssvecacesseajasssensenenosioseaavvaceanovsasansosadenanvanvadsneaveasistaanevodesntonvrsnevistviecteamaetaecsiveneaeanraen 44 Mantak s IN oi as 44 A E COME ETE O 44 OSPE Eege 44 OSPE LS non reaction non reaction VELSIONS csscsssssecesscecssscsscecscsssecsssecscssseescseceesesesscsecseseseseeneseescseseesesee
8. Service Manual OSPE Steering Valve Assembly Assembling OSPE continued Press and turn the shaft seal 7 into position in the housing Draw the inner and outer parts of the assembly tool out of the steering unit bore leaving the guide from the 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 11506577 Rev 0001 August 2015 F302 138 F302 136 F302 139 F302 140 29 30 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued Put the check valve ball 5 into the hole indicated by the circle Screw in the screw 4 using a 12 mm screw 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 11506577 Rev 0001 August 2015 F302 141 F302 142 F302 143 F302 144 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued Screw 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 Sc
9. eeneseeseees 44 Checktorexternal e nina iii 45 Tightening Torques Tightening torques for connections OPSE ccsssssesssssssessssessssecsssecsecsssecsssscsessssucsesucsesucsesscsucassucassucsessssucaesucsesscsesacseasenes 46 L1506577 Rev 0001 August 2015 3 Service Manual OSPE Steering Valve Safety Precautions Safety Precautions 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 A Warning Unintended Machine Movement Unintended movement of the machine or mechanism may cause injury to the technican or bystanders To prevent uintended movement secure the machine or disable disconnect the mechanism while servicing A Warning Flammable Cleaning Solvents Some cleaning solvents are flammable To eliminate the risk of fire do not use cleaning solvents in an area where a source of ignition may be present A Warning Fluid under Pressure 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 immedia
10. eering Valve Assembly Assembling OSPE continued Screw in the plugs 253 and 254 using a 6 mm Hex key 20 3 Nm These plugs not present in all OSPE s Place O rings 330 331 332 on cartridge spool 246 Screw in the cartridge spool 246 using a 7 8 inch Ol ring spanner 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 11506577 Rev 0001 August 2015 F302 104 F302 090 F302 165 F302 166 39 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued OSPE with priority valve Place the O ring 312 on plug 207 with 17 mm key profile Screw in the plug 207 using a 17 mm O socket spanner 45 5 Nm OSPE without priority valve Place the O rings 312 313 on plug 207 with 8 mm Ol Hex key profile Screw in the plug 207 using a 8 mm Hex key 45 5 Nm Insert the EH L amp R cut off spool 242 with the spring bore pointing outwards F302 167 F302 174 Insert the spring 241 Dimension of this spring Wire diameter 2 2 mm Length 50 2 0 8 mm F302 168 Place the O ring 312 on plug 243 Screw in the plug
11. ering 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 gt Number of turns must be 600 60 10 turns Remove pump supply to P port of OSPE and plug the P port Remove the steering cylinder connection T must still be connected to tank of pump station OSPE LSRM Land R ports are connected through the spool sleeve set in neutral steering wheel must be untouched during setting of shock valves 1 Plug the L port and apply pump pressure to the R port The shock valves are to be set at an oil flow of 3 l min The supply must be limited to max 280 bar on the pump station 2 Screw one of the shock valves item 64 outwards until pressure is reduced to the lower specified value 15 20 bar and flows comes out of the T port e g 235 240 bar of specified value 220 240 bar 3 Screw the other shock valve item 64 outwards until pressure is reduced to the lower specified value 0 5 bar and check that flow out of T port continues e g 220 225 bar of specified value 220 240 bar OSPE LS non reaction non reaction versions The shock valves are to be set at an oil flow of 3 min applied to one of the servo ports Land Rat a time The supply must be limited to maximum 280 bar on the pump station 11506577 Re
12. f 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 surface F301 732 10 11506577 Rev 0001 August 2015 Service Manual OSPE Steering Valve Tools Tools continued Tool for removing assembling pilot relief valve cartridge Code number 15516494 Torque wrench 0 70 Nm 13 17 19 and 32 mm socket spanner 2 2 75 3 4 5 6and 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 F300 939 11506577 Rev 0001 e August 2015 11 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE Dismantling OSPE Place the unit in the holding tool on steering column end Screw out the 4 screws for the 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 0 socket or ring spanner O ring 312 is fitted on plug 243 Remove the spring 241 12 L1506577 Rev 0001 August 2015 T k 7 igen imi hiil TC 1 F302 079 F302 080 F302 081 F302 082 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued Remove the EH L amp R cut off spool 242 Screw out the plug 207 If the OSPE i
13. g 22 No 1000 Jin Hai Rd 2800 East 13th Street Krokamp 35 Nordborgvej 81 Jin Qiao Pudong New District Ames IA 50010 USA D 24539 Neum nster Germany DK 6430 Nordborg Denmark Shanghai China 201206 Phone 1 515 239 6000 Phone 49 4321 871 0 Phone 45 7488 2222 Phone 86 21 3418 5200 Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 11506577 Rev 0001 August 2015 www danfoss com O Danfoss A S 2015
14. ications expertise we work closely with our customers to ensure Pumps and Motors exceptional performance for a broad range of off highway vehicles e Displays We help OEMs around the world speed up system development reduce costs and bring e Electrohydraulic Power vehicles to market faster Steering e Electrohydraulics Danfoss Your Strongest Partner in Mobile Hydraulics e Hydraulic Power Steering Go to www powersolutions danfoss com for further product information e Integrated Systems Wherever off highway vehicles are at work so is Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And e Joysticks and Control with an extensive network of Global Service Partners we also provide comprehensive global Handles eeler service for all of our components Software Please contact the Danfoss Power Solution representative nearest you e Open Circuit Axial Piston Pumps e Orbital Motors e PLUS 1 GUIDE e Proportional Valves e Sensors e Steering e Transit Mixer Drives Comatrol www comatrol com Schwarzmiuller Inverter www schwarzmueller Local address inverter com Turolla www turollaocg com Hydro Gear www hydro gear com Daikin Sauer Danfoss www daikin sauer danfoss com Danfoss Power Solutions Trading Danfoss Danfoss Danfoss Shanghai Co Ltd Power Solutions US Company Power Solutions GmbH amp Co OHG Power Solutions ApS Buildin
15. l out of the sleeve 11506577 Rev 0001 August 2015 F302 127 F302 128 F302 129 F302 130 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued Press the neutral position springs 14 out of the slot of the spool F301 808 Remove dust seal 9 and shaft seal Roto Glyd 7 carefully with a screw driver or similar tool F302 131 The steering unit OSPED is now completely dismantled F302 132 Cleaning Clean all parts carefully in Shellsol K or similar cleaner fluid RK Inspection and replacement Replace all seals and washers Check all parts carefully and make any replacements as is necessary L1506577 Rev 0001 August 2015 25 Service Manual OSPE Steering Valve Assembly Assembling OSPE Assembling OSPE Place the two flat neutral position springs from item 14 in the slot of the spool from item 1 Place the curved springs between the flat ones and press them into place F301 810 Configuration of spring set 14 There can be different numbers of curved springs depending on configuration of spring set There can be 2 4 or 6 curved springs 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
16. ll in new design e 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 Bulletin ST2014 0139 Service literature HN 21 ZA 52 is valid for gear set end of OSPED in old version L1506577 Rev 0001 August 2015 OSPE Steering Valve Exploded View and Seal Kit Service Manual OSPE exploded view P301 786 A O DAS ST Ge O So SY KS l IAS lt NY Y d 2 O_O LP N s ST DA gt 11506577 Rev 0001 August 2015 Service Manual OSPE Steering Valve Exploded View and Seal Kit OSPE parts list OSPE parts list rr eS torque CI A O ong Co ERE O CI ooo CT A CO o O A A S CI A CN IS O CS CO A A oe ln DR ECG CT A A CI E eg DEE CI E CI A A ER CAC A A O ring 79 4 x 2 0 mm OSPED 6 88 E O ring 79 4 x 12 0 mm OSPE E e Foo DEE GEES e po a p CO EIN DES ES EE DEE s po ml DOE C n w o o P o L1506577 Rev 0001 August 2015 7 Dashes Service Manual OSPE Steering Valve Exploded View and Seal Kit OSPE parts list continued Number per unit Tigtening torque i i Some Zog AAA E ETE CS EIA A EXITOS CIA ED seme Some Seege eng Od A ETT IS AS EIA OA om O EIA CA CTE TS OS ESTAN A ommon OS o CS CTI CA EAN CUTE AS ECON o fe Dag OO omoose COMA p CS CUTE CONAN EAN o CUTE TES AAA ECON o CUT O ECO
17. ng are parallel with the port face for P T L and R connections vi Ee a wi igh d vuggmun F302 154 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 O socket spanner 30 6 Nm pa OSPE Has 7 identical screws 7x 31 AN Set lt F302 155 Replace the unit in the holding tool on gear set end Use appropriate support under the mounting surface for the PVE to support the steering valve L1506577 Rev 0001 August 2015 35 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued The OSPE can now be function tested manually it must be possible to rotate input shaft with torque lt 3 5 Nm 31 Ibfsin Place the dust seal ring 9 in the housing Fit the 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 Ibf in Place one ball 61 in each of the shock valve cavities 36 L1506577 Rev 0001 August 2015 be F302 156 F302 157 F302 158 F302 159 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued Place springs with trust pads 62 over the
18. or other OLS 80 with same orifice and spring specification Dynamic orifice 01 0 mm LS orifice 1 2 mm Spring 7 bar Connect LS port of OSPE with LS port of OLS 8 Connect T port of OSPE to tank Steering test Dur 1 2 Screw the adjusting screws of shock valves to block Screw clockwise as much as possible to a torque lt 5 Nm to ensure the shock valves do not open during steering test or setting of pilot relief valve ing the testing no motor effect disturbing vibrations noise sticking or other irregularities must occur Start the pump the pump flow is adjusted to approx 25 l min and pump pressure control must be set to app 70 bar Let the supplied oil flow through the steering unit for a few minutes At the same time the steering wheel is to be rotated a few times in both directions to bleed of air from the unit and the system Operate the steering wheel by approx 10 rpm in a smooth manner from end stroke to end stroke of the steering cylinder for at least 5 cycles Make sure pressure P T 70 bar can be achieved when steering against end stroke If this is not possible the adjusting screw of the pilot relief valve item 95 of exploded view must be turned clockwise until P T 70 bar is achievable L1506577 Rev 0001 August 2015 43 Service Manual OSPE Steering Valve Test and valve setting of OSPE Pilot relief valve The pump flow is adjusted to approx 25 l min and pressure to max
19. ove the end cover 36 sideways 18 11506577 Rev 0001 August 2015 F301 103 F302 104 F302 105 F302 106 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued OSPED Lift the gearwheel set 115 off the unit Remove 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 11506577 Rev 0001 August 2015 F302 107 F302 108 F302 109 F302 110 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued OSPED Remove 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 20 11506577 Rev 0001 August 2015 F302 111 F302 112 F302 113 F302 114 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued Remove the O ring 6 from housing Screw out threaded bushing 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 11506577 Rev 0001 August 2015 F302 115 F302 116 F302 117 F302 118 21 Service Manual OSPE Steering Valve
20. rew in the plug 225 using a 5 mm Hex key 10 2 Nm 11506577 Rev 0001 August 2015 F302 145 F302 146 F302 147 31 Service Manual OSPE Steering Valve Assembly 32 Assembling OSPE continued Place 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 11506577 Rev 0001 August 2015 F302 148 F302 149 F302 150 F302 151 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued Insert the O ring 6 in the grove on the housing F302 152 Place the distributor plate 34 OSPED the small 24 mm hole of the plate 34 must be placed above the 43 mm hole in the housing The radial channel groove of the plate 34 must be facing the housing side F302 153 Guide the cardan shaft 13 down into the bore so that the slot is parallel with the connection flange for P T L and R ports and lines up with the cross pin 12 F302 113 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 and cardan shaft can only be assembled with correct timing F302 112 11506577 Rev 0001 A
21. s with priority valve integrated Use a 17 mm O socket 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 L1506577 Rev 0001 August 2015 F302 084 F302 085 F302 086 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued Screw off the nut 248 using a 19 mm O 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 O ring spanner O rings 330 331 332 are fitted on cartridge spool 246 14 L1506577 Rev 0001 August 2015 F302 087 F302 090 Service Manual OSPE Steering Valve Dismantling Dismantling OSPE continued Replace the unit in the holding tool on the gear set end Use appropriate support made of plastic brass or aluminum under the mounting surface for the PVE to support the steering valve F302 091 Screw out the adjusting screws for shock valves 64 using a 5 mm Hex key O ring 40 is fitted on screw 64 F302 092 Remove the springs with trust pads for shock valves 62 F302 093 Remove the balls for shock valves 61 F302 094 11506577 Rev 0001 August 2015 15 Service Manual OSPE Steering Valve
22. side Make sure the neutral position springs 14 are placed into the slot F302 133 26 L1506577 Rev 0001 August 2015 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued Line up the spring set 14 Guide the ring 16 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 11506577 Rev 0001 August 2015 F301 812 F302 134 F302 135 F301 815 27 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued Caution Assembly pattern for standard bearing 1 Outer bearing race 2 Needlebearing 3 Inner bearing race 4 Spool 5 Sleeve The inside chamfer on the inner bearing race must face the chest of the inner spool 150 383 10 Place the steering valve housing with the port face down on the work bench Guide the outer part of the assembly tool into the bore for the spool sleeve set 1 F302 136 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 F300 985 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 the bottom F302 137 28 L1506577 Rev 0001 August 2015
23. tely if you are cut by hydraulic fluid A Warning Personal Safety Protect yourself from injury Use proper safety equipment including safety glasses at all times A Warning Product Safety Steering valves are safety components and therefore it is extremely important that the greatest care is taken when servicing these products There is not much wear on a steering valve and therefore they normally outlast the application they are built into Therefore the only recommended service work on steering valves is e Changing seals and o rings e Disassemble clean and assemble if contaminated e Make hydraulic testing including valve setting L1506577 Rev 0001 August 2015 Service Manual OSPE Steering Valve Service Literature Symbols Used in Danfoss Literature bi Non removable part use a new part O External hex head Internal hex head Lubricate with hydraulic fluid Inspect for wear or damage Note correct orientation Mark orientation for reinstallation Torque specification Si Press in press fit ES Pull out with tool press fit OSPE versions This service literature is valid for e All OSPE s with single stage gear set e All 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 e OSPED s with product code number higher than 11113069 are a
24. two balls Place O rings 40 on adjusting screws 64 Screw in the two adjusting screws 64 using 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 O socket spanner 45 5 Nm L1506577 Rev 0001 August 2015 F302 161 F302 163 37 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued Place O rings 311 on plugs 209 Screw in the plugs 209 usinga8 mm Hex key 45 5Nm The left side positioned plug is only present on OSPE s with priority valve integrated Place back up ring 303 O rings 301 302 304 filter 305 and locking ring 300 in on cartridge 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 F302 101 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 F301 103 Screw in the orifice 222 using a 3 mm Hex key 3 0 5 Nm This orifice is not present in all OSPE s WA F302 102 38 L1506577 Rev 0001 August 2015 Service Manual OSPE St
25. ugust 2015 33 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued OSPED Place and rotate the cardan shaft 120 with the big diameter end until it moves in gear with gear wheel of gear set 30 OSPED Place the middle distributor plate 116 so that the channel holes match the 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 Land R connections Make sure that channel holes of the valve housing assembly 122 match the holes in the distributor plate 116 34 L1506577 Rev 0001 August 2015 F302 111 F302 110 F302 173 F301 827 Service Manual OSPE Steering Valve Assembly Assembling OSPE continued OSPED Place the rear distributor plate 117 so that the channel holes match the holes in valve housing assembly 122 F301 828 OSPED Place the 2 O rings 39 in the two groves in the gear rim Fit the gearwheel with rim 115 on the cardan shaft 120 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 and cardan shaft can only be assembled with correct timing F302 107 Place the end cover 36 in position Ensure that the bar codes and writi
26. v 0001 August 2015 Gef Service Manual OSPE Steering Valve Test and valve setting of OSPE Adjust the pressure R T L T by adjusting screws of shock valves item 64 to the specified value for the shock valve setting for the code in question Check for external leakage After testing 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 11506577 Rev 0001 August 2015 45 Service Manual OSPE Steering Valve Tightening Torques Tightening torques for connections OPSE Tightening Torques for Connections OSPD V2 Connections Maximum tightening torque Nm Ibf in With cutting edge With copper washer With alum Washer Oring 80 708 55 486 50 442 100 885 65 575 80 708 60 531 46 L1506577 Rev 0001 August 2015 Service Manual OSPE Steering Valve 11506577 Rev 0001 August 2015 47 Products we offer Danfoss Power Solutions is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions e Bent Axis Motors that excel in the harsh operating conditions of the mobile off highway market Building on e Closed Circuit Axial Piston our extensive appl
27. with PVES PVED CC or PVED CL connect battery power cables with on off switch to the coil of control valve for mode select 247 Voltage must meet the specification for the code For OSPE with PVED CLS the coil 247 is controlled by the PVED CLS Connect voltage supply and signal input for the PVE Connect P port to pump supply Block LS port with steel plug Connect T and EF ports separately to tank of pump station T pressure should not exceed 5 bar The maximum allowed T pressure is 25 bar The pump supply circuit should not exceed 210 bar P T Screw the adjusting screws of shock valves to block Screw clockwise as much as possible to a torque lt 5 Nm to ensure the shock valves do not open during steering test or setting of pilot relief valve up OSPE without integrated priority valve Connect double rod cylinder to L and R ports of OSPE Connect pressure gauges to all ports of OSPE Connect steering column and steering wheel to the input shaft of the OSPE If OSPE with PVES PVED CC or PVED CL connect battery power cables with on off switch to the coil of control valve for mode select 247 Voltage must meet the specification for the code For OSPE with PVED CLS the coil 247 is controlled by the PVED CLS Connect voltage supply 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
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