Danfoss OSPE User manual

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

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

Safety Precautions Safety Precautions............................................................................................................................................................................4
Service Literature Symbols Used in Danfoss Literature..........................................................................................................................................5
OSPE versions.....................................................................................................................................................................................5
Exploded View and Seal Kit OSPE exploded view........................................................................................................................................................................6
OSPE parts list....................................................................................................................................................................................7
Tools Tools for OSPE................................................................................................................................................................................. 10
Dismantling Dismantling OSPE..........................................................................................................................................................................12
Assembly Assembling OSPE...........................................................................................................................................................................26
Test and valve setting of OSPE
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 connections OPSE............................................................................................................................46
Service Manual OSPE Steering Valve
Contents
L1506577 • Rev 0001 • August 2015 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 technican or bystanders.
To prevent uintended 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
•Make hydraulic testing including valve setting.
Service Manual OSPE Steering Valve
Safety Precautions
4L1506577 • Rev 0001 • August 2015

Symbols Used in Danfoss Literature
•= Non removable part, use a new part
•= External hex head
•= Internal hex head
•= Lubricate with hydraulic fluid
•= Inspect for wear or damage
•= Note correct orientation
•= Mark orientation for reinstallation
•= Torque specification
•
= Press in - press fit
•= Pull out with tool - press fit
OSPE versions
This service literature is valid for:
•All OSPE’s with single stage gear set
•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:
•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 Bulletin
ST2014-0139.
Service literature HN.21.ZA.52 is valid for gear set end of OSPED in “old” version.
Service Manual OSPE Steering Valve
Service Literature
L1506577 • Rev 0001 • August 2015 5

OSPE exploded view
64
40
41
63
13
4
5
225
224
202
205
9
310
12
62 61
233
204
243
241
207
207
216
85
86
87
221
222
3
249 248
204
312
313
312
320
247
242
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
6L1506577 • Rev 0001 • August 2015

OSPE parts list
OSPE parts list
OSPE Number per unit Item Tigtening
torque
Spool/Sleeve set 1 1 -
Housing 1 3 -
Screw 1 4 1.5 ±0.3 Nm
Ball for emergency steering Ø8.5 mm 1 5 -
O-ring Ø79.4 x Ø2.0 mm 1 6 -
Shaft seal 1 7 -
Dust seal ring 1 9 -
Cross pin 1 12 -
Cardan sharft 1 13 -
Set of springs 1 14 -
Ring 1 16 -
Bearing assembly 1 18 -
Gear set 1 30 -
Short screw (OSPED) 1 27 30 ±6 Nm
Screws (OSPED) 6 31 30 ±6 Nm
Screws (OSPE) 7 31 30 ±6 Nm
Valve plate 1 34 -
Washers 7 35 -
End cover 1 36 -
O-ring Ø79.4 x Ø2.0 mm (OSPED) 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 1 95 20 ±3 Nm
Gear set 1 115 -
Valve plate 1 116 -
Valve plate 1 117 -
Cardan shaft 1 120 -
Valve housing assembly 1 122 -
Spool, EH steering 1 202 -
Spool priority valve 1 203 -
PVE 1 204 -
Plug 1 205 45 ±5 Nm
Service Manual OSPE Steering Valve
Exploded View and Seal Kit
L1506577 • Rev 0001 • August 2015 7

OSPE parts list (continued)
OSPE Number per unit Item Tigtening
torque
Plug 1 207 45 ±5 Nm
Plugs 2 209 45 ±5 Nm
Spring 1 213 -
Cone pilot supply 1 214 -
Spool pilot supply 1 215 -
Plug 1 216 30 ±3 Nm
Check valve, LS 1 221 3.5 ±0.5 Nm
Orifice, LS 1 222 3.5 ±0.5 Nm
Spool pvfc 1 224 -
Plug 1 225 15 ±2 Nm
Orifice PP 1 230 3.5 ±0.5 Nm
Spring 1 231 -
Orifice Dynamic 1 232 1 ±0.1 Nm
Screws 4 233 8 ±1 Nm
Spring 1 241 -
Spool reaction/EH L&R cut off 1 242 -
Plug 1 243 45 ±5 Nm
Cartridge spool, pilot dump 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 Ø10.0 x Ø2.0 mm 3 320 -
O-ring Ø30.0 x Ø2.5 mm 1 321 -
O-ring Ø8.0 x Ø2.0 mm 1 322 -
Filter 1 323 -
O-ring ø7.65 x ø1.78 mm 1 330 -
O-ring ø9.25 x ø1.78 mm 1 331 -
O-ring ø13.5 x ø2.08 mm 1 332 -
Service Manual OSPE Steering Valve
Exploded View and Seal Kit
8L1506577 • Rev 0001 • August 2015

OSPE seal kit and spare parts
Spare parts list Code No. Item
Coil, Deutsch®: D08 12V DE 322113 11084688 247
Coil, AMP: D08 12V AJE 321930 11084690 247
Spare part bag containing:
Cartridge spool for pilot dump, Nut and O-ring 11085713 246, 248, 249
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 Code No. Containing seal kits, codes
Seal kit KIT OSPE complete 11160838 150N4041, 11160415, 155L6870,
157B4997, 120433
Service Manual OSPE Steering Valve
Exploded View and Seal Kit
L1506577 • Rev 0001 • August 2015 9

Tools for OSPE
Tools
Holding tool for the entire steering valve.
Material: Appropriate metal or hard plastic
This tool is not available from Danfoss.
90±1
ø46±0.5
120±2
2xø15±0.1
5±1
20±1
150±2
100±2
7x51.4˚
ø64
7xø15+0.5/-0
1x45˚
93±0.5
90±1
P301 787
Assembly tool for dust seal.
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
surface.
Service Manual OSPE Steering Valve
Tools
10 L1506577 • Rev 0001 • August 2015

Tools (continued)
Tool for removing/assembling pilot relief valve cartridge:
Code number: 155L6494
Torque wrench 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

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 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

Dismantling OSPE (continued)
Remove the EH L&R cut off spool (242).
Screw out the plug (207).
If the OSPE is with priority valve integrated:
Use a 17 mm 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).
Service Manual OSPE Steering Valve
Dismantling
L1506577 • Rev 0001 • August 2015 13

Dismantling OSPE (continued)
Screw off the nut (248) using a 19 mm 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

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.
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

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 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.
Replace the unit in the holding tool on steering column
end.
Service Manual OSPE Steering Valve
Dismantling
16 L1506577 • Rev 0001 • August 2015

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.
Service Manual OSPE Steering Valve
Dismantling
L1506577 • Rev 0001 • August 2015 17

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)
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

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).
Service Manual OSPE Steering Valve
Dismantling
L1506577 • Rev 0001 • August 2015 19

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.
Service Manual OSPE Steering Valve
Dismantling
20 L1506577 • Rev 0001 • August 2015