Danfoss OSQA User manual

Service Manual
Flow amplifier
OSQA/OSQB
powersolutions.danfoss.com

Revision history Table of revisions
Date Changed Rev
July 2016 First edition 0101
Service Manual
OSQA/OSQB
2 | ©Danfoss | July 2016 HN25D293 | AX00000127en-US0101

Introduction Safety precautions............................................................................................................................................................................4
Symbols used in this literature.................................................................................................................................................... 4
OSQ versions......................................................................................................................................................................................5
Technical specifications Exploded view................................................................................................................................................................................... 6
Parts list................................................................................................................................................................................................6
OSQA and OSQB parts list........................................................................................................................................................6
OSQ spare parts list.................................................................................................................................................................... 8
Tools......................................................................................................................................................................................................8
Disassembly Dismantling counter pressure valve..........................................................................................................................................9
Removing pressure relief valve ................................................................................................................................................11
Removing end cover at PP-connection................................................................................................................................. 12
Removing end cover at LS-connection..................................................................................................................................13
Unscrew orifices, throttle check valve....................................................................................................................................16
Housing and end cover with accessories..............................................................................................................................16
Spools with accessories............................................................................................................................................................... 17
Dismantling directional spool...................................................................................................................................................17
Priority valve spool number of orifices...................................................................................................................................17
Dismantling priority valve spool.............................................................................................................................................. 18
Dismantling amplifier spool.......................................................................................................................................................19
Shock and suction valves............................................................................................................................................................23
Cleaning............................................................................................................................................................................................ 24
Inspection and replacement......................................................................................................................................................24
Lubrication....................................................................................................................................................................................... 24
Assembly Assembling shock, suction, and check valve.......................................................................................................................25
Assembling amplifier spool........................................................................................................................................................26
Assembling priority valve spool............................................................................................................................................... 28
Assembling directional spool....................................................................................................................................................29
Installing orifice and throttle check valve.............................................................................................................................29
Installing shock valves..................................................................................................................................................................30
Assembling pressure relief valve..............................................................................................................................................31
Installing OSQB back pressure valve.......................................................................................................................................32
Installing spools..............................................................................................................................................................................33
Installing PP end cover.................................................................................................................................................................34
Installing LS end cover.................................................................................................................................................................37
Plastic plugs..................................................................................................................................................................................... 39
Testing Set-up for testing........................................................................................................................................................................... 40
Steering test using steering unit type OSPBX LS................................................................................................................40
Pilot relief valve...............................................................................................................................................................................41
Neutral positioning....................................................................................................................................................................... 41
Manual steering test..................................................................................................................................................................... 41
Service Manual
OSQA/OSQB
Contents
©Danfoss | July 2016 HN25D293 | AX00000127en-US0101 | 3

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.
W
Warning
Unintended Machine Movement
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
To prevent unintended movement, secure the machine or disable / disconnect the mechanism while
servicing.
W
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.
W
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 immediately if you are cut by hydraulic fluid.
W
Warning
Personal Safety
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
W
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:
•Changing seals and o-rings
•Disassemble, clean, and assemble if contaminated
•Hydraulic testing, including valve setting
Symbols used in this literature
Non removable part, use a new part Note correct orientation
External hex head Mark orientation for reinstallation
Internal hex head Torque specification
Lubricate with hydraulic fluid Press in - press fit
Inspect for wear or damage Pull out with tool - press fit
Service Manual
OSQA/OSQB
Introduction
4 | ©Danfoss | July 2016 HN25D293 | AX00000127en-US0101

OSQ versions
This service literature is valid for:
•OSQA: Flow-Amplifier without back pressure valve in HT
•OSQB: Flow-Amplifier with back pressure valve in HT
Service Manual
OSQA/OSQB
Introduction
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Exploded view
OSQA and OSQB exploded view
1
12
38
14 15 40 41 39
30
29
28
27
10
5
20
20
49
49.2
47
48
46
45
23
23.2
22.2
22
21
25
13
37.1
37.2
37.5 37.4
37.3
2
26
27
28
29
30
37
57
57
58
58
59
6
9
20.11
20.11
26
36
66
65
70
80
81
82
83
4
3
7
11
160
24
81
80
82 83
kwa1464729220764
Parts list
OSQA and OSQB parts list
Parts list
Part Number per unit Item Tightening torque
Housing 1 1 —
Priorty valve spool 1 2 —
Plug 1 3 10 ± 3 N·m
Throttle/check valve 1 4 10 ± 3 N·m
Compress spring 1 5 —
Throttle/check valve 1 6 10 ± 3 N·m
Plug 1 7 BSP: 40 ± 5 N·m
UNF: 15 ± 3 N·m
Orifice, LS 1 9 10 ± 3 N·m
Spring stop 1 10 —
Orifice, dynamic 1 11 5 ± 1 N·m
Outer spool amplifier 1 12 —
Compress spring 1 13 —
Service Manual
OSQA/OSQB
Technical specifications
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Parts list (continued)
Part Number per unit Item Tightening torque
Inner spool, amplifier 1 14 —
Compress spring 1 15 —
Shock valve 2 20 —
O-ring Ø24 x 2 mm 2 20.11 —
Valve seat 1 21 20 ± 3 N·m
Pilot cone 1 22 —
Spring 1 22.2 —
Adjusting screw 1 23 —
O-ring Ø9 x 2 mm 1 23.2 —
Plug 1 24 —
Directional spool 1 25 —
Orifice 2 26 5 ± 1 N·m
Spring stop 2 27 —
Compress spring 2 28 —
Compress spring 2 29 —
Spring stop 2 30 —
Orifice 1 36 5 ± 1 N·m
Check valve 1 37 20 ± 3 N·m
Screw 1 37.1 5 ± 1 N·m
Compress spring 1 37.2 —
O-ring Ø10.3 x 2.4 mm 1 37.3 —
Valve seat 1 37.4 —
Ball 1 37.5 —
Pin 2 38 —
Locking ring 2 39 —
Plug 1 40 —
Orifice 1 41 5 ± 1 N·m
Compress spring, OSQB only 1 45 —
Piston, OSQB only 1 46 —
Compress spring, OSQB only 1 47 —
Ball, OSQB only 1 48 —
Plug, OSQB only 1 49 25 ± 3 N·m
O-ring Ø23.3 x 2.4 mm, OSQB only 1 49.2 —
O-ring Ø35 x 2 mm 4 57 —
O-ring Ø40 x 2 mm 4 58 —
O-ring Ø10 x 2 mm 2 59 —
Cover 1 65 —
Cover 1 66 —
Model/code label 1 70 —
Spring washer 16 80 —
Screw 16 81 25 ± 5/-0 N·m
Spring washer 2 82 —
Screw 2 83 80 ± 10 N·m
Plug with O-ring 1 160 25 ± 5 N·m
Service Manual
OSQA/OSQB
Technical specifications
©Danfoss | July 2016 HN25D293 | AX00000127en-US0101 | 7

OSQ spare parts list
Spare parts list
Spare parts Code number Item
Seal kit NBR for OSQ 150F0278 20.11, 23.2, 37.3, 49.2, 57, 58 , 59, and
two aluminum washers for pilot relief
valve of OSQ from before week 43,
year 2004
Seal kit Viton for OSQ 11020933 57, 58 , 59
Pilot relief valve kit 11011038 21, 22, 22.2, 23, 23.2
Shock and suction valves complete, 140-160 bar 150F0281 20, 20.11
Shock and suction valves complete, 165-185 bar 150F0282 20, 20.11
Shock and suction valves complete, 200-220 bar 150F0286 20, 20.11
Shock and suction valves complete, 215-235 bar 150F0283 20, 20.11
Shock and suction valves complete, 230-250 bar 150F0284 20, 20.11
Shock and suction valves complete, 270-290 bar 150F0285 20, 20.11
Tools
Tools needed for assembly / disassembly
•Hexagon keys 4, 5, 6, 8, and 10 mm
•Ratchet for socket spanners
•Hexagon socket for external hexagon 6, 13, 17, and 19 mm
•Hexagon socket for internal hexagon 8 and 10 mm
•Multigrip pliers
•Ring spanner 13 mm
•Screwdrivers 3 and 10 mm
•Steel mandrels 3, 5 and 8 mm
•Torque wrench for 12 daNm [1060 lbf in]
•Magnetic rod
•Hook
These tools are not available from Danfoss.
Service Manual
OSQA/OSQB
Technical specifications
8 | ©Danfoss | July 2016 HN25D293 | AX00000127en-US0101

OSQB: OSQ with back pressure valve in HT
Place the unit on a work bench.
Dismantling counter pressure valve
1. Screw out the plug with O-ring (49) using an 8 mm Hex key.
2. Take out the small spring (47) using a hook.
Service Manual
OSQA/OSQB
Disassembly
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3. Take out ball (48) using a magnetic rod.
4. Take out the piston (46) using a hook.
5. Take out the spring (45) using a hook.
Dismantled counter pressure valve
Service Manual
OSQA/OSQB
Disassembly
10 | ©Danfoss | July 2016 HN25D293 | AX00000127en-US0101

Removing pressure relief valve
1. Remove plug (24) using a 2 mm screw driver.
Some special versions of OSQ have a cover plug (160) assembled on the top of the pilot relief valve. In
such cases, use a 24 mm socket spanner.
2. Screw out the adjusting screw (23) using a 6 mm Hex key.
O-ring (23.2) is fitted to the screw (23).
3. Remove the spring (22.2) with cone (22) using a hook or magnet rod.
Service Manual
OSQA/OSQB
Disassembly
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4. Screw out the seat (21) using a 6 mm socket spanner.
Removing end cover at PP-connection
1. Unscrew screws (8x81) with spring washer (8x80) using a 13 mm socket spanner and screw (83)
with spring washer (82) using a 10 mm Hex key.
2. Remove end cover (66).
Spring stop (30) and springs (28, 29 and 13) will follow the end cover.
Service Manual
OSQA/OSQB
Disassembly
12 | ©Danfoss | July 2016 HN25D293 | AX00000127en-US0101

3. Remove stop (27) from directional spool (25).
Removing end cover at LS-connection
1. Unscrew screws (8x81) with spring washer (8x80) using a 13 mm socket spanner and screw (83)
with spring washer (83) using a 10 mm Hex key.
2. Remove end cover (65).
Spring stops (10 and 30) and springs (28 and 29) will follow the end cover.
Service Manual
OSQA/OSQB
Disassembly
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3. Remove spring stop (27) for directional spool (25).
4. Remove spring (5) for priority spool (2).
5. Remove directional spool (25).
Service Manual
OSQA/OSQB
Disassembly
14 | ©Danfoss | July 2016 HN25D293 | AX00000127en-US0101

6. Remove amplifier spool (12).
7. Remove priority valve spool (2).
8. Remove shock valves (2x20) with screwdriver and hexagon key or mandrel.
Service Manual
OSQA/OSQB
Disassembly
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Unscrew orifices, throttle check valve
1. Unscrew orifice (9) in LS-connection using a 6 mm Hex key.
2. Unscrew throttle check valve (6) (if present) in PP-connection using a 6 mm Hex key.
3. Unscrew orifice (36) in housing using a 4 mm Hex key.
Housing and end cover with accessories
Service Manual
OSQA/OSQB
Disassembly
16 | ©Danfoss | July 2016 HN25D293 | AX00000127en-US0101

Spools with accessories
Dismantling directional spool
Use a mandrel for holding the spool, unscrew orifice (26) using a 4 mm Hex key.
Dismantled directional spool (25) and orifice (26)
Priority valve spool number of orifices
Depending on versions this spool has none, 1, or 2 orifices:
•OSQ static with external PP: the priority valve spool has no orifice
•OSQ static with internal PP: the priority valve spool has throttle/check valve (4)
•OSQ dynamic with external PP: the priority valve spool has plug (3) and orifice, dynamic (11)
•OSQ dynamic with internal PP: the priority valve spool has throttle/check valve (4) and orifice,
dynamic (11)
‒As shown in Dismantling priority valve spool on page 18
Service Manual
OSQA/OSQB
Disassembly
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Dismantling priority valve spool
1. Unscrew throttle/check valve (4) using a 8 mm Hex key and multigrip pliers.
2. Unscrew orifice, dynamic (11) using a 4 mm Hex key and multigrip pliers.
Dismantled priority valve spool (25) with throttle/check valve (4) and orifice, dynamic (11)
Service Manual
OSQA/OSQB
Disassembly
18 | ©Danfoss | July 2016 HN25D293 | AX00000127en-US0101

Dismantling amplifier spool
1. Be careful not to damage the locking ring.
Carefully remove, from the amplifier spool (12), the locking ring (39) from the recess using a 3 mm
screwdriver.
a) Carefully guide the locking ring (39) back.
2. Be careful not to damage the locking ring.
Carefully take the other locking ring (39) from the recess and guide it back using a 3 mm screwdriver.
Service Manual
OSQA/OSQB
Disassembly
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a) Press out pin (38) using a 3 mm screwdriver or mandrel.
b) Take out the plug (40).
c) Take out the spring (15).
Service Manual
OSQA/OSQB
Disassembly
20 | ©Danfoss | July 2016 HN25D293 | AX00000127en-US0101