Danfoss PVG 100 Building instructions

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MAKING MODERN LIVING POSSIBLE
Service and Parts Manual
Proportional Valves
PVG 100

2
Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
Contents
PVG 100 sectional drawing.............................................................................................................................................3
Installation and plug orientation..................................................................................................................................4
Installation and identication........................................................................................................................................5
Maximum ow setting .................................................................................................................................................6-7
Connections .........................................................................................................................................................................8
Tightening torques............................................................................................................................................................8
Installation of lever ............................................................................................................................................................9
Pressure setting, PVP.........................................................................................................................................................9
Adjustment of PVE.......................................................................................................................................................... 10
Installation and technical data for PVPP................................................................................................................. 11
Pilot drain connection ................................................................................................................................................... 11
PVMR disassembly .......................................................................................................................................................... 12
PVMR/F assembly............................................................................................................................................................ 13
Tightening torques and widths across ats........................................................................................................... 13
Main spool assembly for PVMR .................................................................................................................................. 14
Float spool assembly for PVMF................................................................................................................................... 15
PVPF, open center pump side module ..............................................................................................................16-17
PVPE, PVPD and Pilot Shut O..............................................................................................................................18-19
PVPV - closed center pump side module..........................................................................................................20-21
PVPV - closed center pump side module with integrated priority function........................................22-23
PVB, PVBZ, PVLA, and PVLP....................................................................................................................................24-25
PVSI, PVT, and PVTI ...................................................................................................................................................26-27
PVAS assembly kit for PVP with PVSI/PVT.........................................................................................................28-29
PVAS assembly kit for PVP with PVTI..................................................................................................................30-31
PVBS, main spool.......................................................................................................................................................32-33
PVM, mechanical activation ..................................................................................................................................34-35
PVM, PVMD, PVH, PVMR, and PVMF cover........................................................................................................36-37
Electrical activation with Hirschmann connector .........................................................................................38-39
Electrical activation with AMP connector ........................................................................................................40-41
Seal kits for PVG 100....................................................................................................................................................... 42
Function
Service parts
Installation

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520L0888 • Rev BB • Feb 2015
Service and Parts Manual PVG 100 Proportional Valves
PVG 100
sectional drawing
A
P106 002E
1. LS relief valve
2. LS connection
3. Priority spool for CF
4. LS connection for steering unit
5. Shuttle valve
6. Pilot operated check valve, POC
7. LS line
8. Logic cartridge for POC
9. Pressure compensator
10. Shock and suction valve, PVLP
11. Main spool, PVBS
12. Max. oil flow adjustment screws for ports A and B
13. LS comp (LS signal sent back to compensators)
12
9
10
11
TT
P
BA
BA
TT
P
7
6
8
5
1
13
2
3
4
LS
comp.
LS
pump
LS
ST
T
Tport
CF Pport
P
B
Function

4
Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
Installation and plug
orientation
Module of PVB 1 2 3 4 5 6 7 8
L mm 80.0 128.0 176.0 224.0 272.0 320.0 368.0 416.0
L in 3.15 5.04 6.93 8.82 10.71 12.60 14.49 16.38
118
[4.65]
170*
[6.69]
100*
[4]
100*
[4]
170*
[6.69]
L
PVP
M12 x 14.0
4 places
* Room for dismantling
60 Nm
[530 lbf•in]
60 Nm
[530 lbf•in
]
P106 000E
T
A
B
P
DIN mounting
orientation
Installation

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520L0888 • Rev BB • Feb 2015
Service and Parts Manual PVG 100 Proportional Valves
Standard, oil ow direction
and setting of max ow
PVM to the right of PVP
Identication
E101 279E
PVEH/
PVES
PVEA
PVEO
PVH
PVMD
PVMR/
PVMF
PVP
PVM
PVB
PVS
B
A
P-A P-B
7-9 Nm
[61-79 lbf•in]
Q max: P B
Q max: P A
01 03 A 00 0299
Week of manufacture
Year of manufacture
Day of the week
(A = Monday, B = Tuesday ...)
Issue number
Series number
C:
PVG code number, week and year of manufacture
D:
PVP pressure setting
8 Nm
[70 lbf•in]
10 mm
3 mm
-
+
-
+
Q max. B
Q max. A
Q max. B
Q max. A Q max. A Q max. B
C
D
Installation and Identication

6
Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
Option, oil ow direction
and setting of max ow
PVM to the left of PVP
E101 284E
PVEH/
PVES
PVEA
PVEO
PVH
PVMD
PVMR/
PVMF
B
A
PVP
PVB
PVS
P-A
P-B
PVM
7-9 Nm
[61-79 lbf•in]
Q max: P B
Q max: P A
Installation

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520L0888 • Rev BB • Feb 2015
Service and Parts Manual PVG 100 Proportional Valves
Connections, pump side
module, PVP
end plate, PVS
Tightening torque
E101 285E
B
A
T
P
LS
T0
PAccu
LX
Maximum tightening torque
G 3/4 G 1 G 3/4 G 1/4 G 1 G 1 1/4
210 Nm 330 Nm 210 Nm 40 Nm 330 Nm 540 Nm
1850 lbf·in 2920 lbf·in 1850 lbf·in 350 lbf·in 2920 lbf·in 4780 lbf·in
50 Nm 70 Nm 50 Nm 20 Nm 70 Nm 100 Nm
445 lbf·in 620 lbf·in 445 lbf·in 180 lbf·in 620 lbf·in 885 lbf·in
110 Nm 150 Nm 110 Nm 30 Nm 150 Nm 240 Nm
970 lbf·in 1330 lbf·in 970 lbf·in 270 lbf·in 1330 lbf·in 2125 lbf·in
210 Nm 330 Nm 210 Nm 40 Nm 330 Nm 540 Nm
1850 lbf·in 2920 lbf·in 1850 lbf·in 350 lbf·in 2920 lbf·in 4780 lbf·in
1 1/16 in-12 1 5/16 in-12 1 1/16 in-12 9/16 in-18 1 5/16 in-12 1 5/8 in-12
120 Nm 160 Nm 120 Nm 40 Nm 160 Nm 320 Nm
1040 lbf·in 1420 lbf·in 1040 lbf·in 350 lbf·in 1420 lbf·in 2830 lbf·in
Connection
BSPP port connection
With steel washer
With copper washer
With aluminum washer
With cutting edge
UNF port connection
With O-ring
LS, LX, T0
P A/B Gauge: P, Pp, T
PpAccum.
Ppgauge
Pp gauge
(PVP-OC)
PVP-OC shown
Installation

8
Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
Installation of lever
Pressure setting, PVP
P106 007E
Base with an angle of 22.5° Base with an angle of 37.5°
P106 008E
PVP-CC
PVP-OC
360° ~ 120 bar
360° ~ 1740 psi
4 mm
Installation

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520L0888 • Rev BB • Feb 2015
Service and Parts Manual PVG 100 Proportional Valves
PVEH/PVEM/PVES
Adjustment of PVE
when max. lever travel is
exceeded
(PVE is factory-preset)
Check maximum lever travel in neutral position.
1. Make sure the system is supplied with hydraulic power.
2. Connect supply voltage (UDC) (Signal voltage 0.5 x UDC), or cut o the signal voltage (US) on
pin 2.
A
B
m
a
x
.
2
[
0
.
0
8
]
m
a
x
.
2
[
0
.
0
8
]
Lever travel exceeded in PVG 100 Direction of rotation for adjustment of position transducer
Direction A
Direction B
Turn of transducer Movement of lever
1/4
1/2
3/4
1.5 mm [0.06 in]
3.0 mm [0.12 in]
4.5 mm [0.18 in]
Installation

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Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
Installation
Installation and technical
data for pvpp (solenoid
operated pilot drain)
When installing the wire remember to
connect the built-in diode to the plug
pins.
Position Max. tightening torque
124 mm 45 Nm
[0.94 in
][
400 lbf·in]
220 mm 5 Nm
[0.79 in
][
44 lbf·in]
Max. operation pressure350 bar [5076 bar]
Max. coil surface temperature 155°C [311°F]
Rated voltage 12 V ––
__ 24 V –– __
Current consumtion 22°C (71,6°F) coil temperature1.55
A0
.78 A
110°C (230°F) coil temperature1.00
A0
.50 A
Power consumtion 22°C (71,6°F) coil temperature19
W1
9 W
110°C (230°F) coil temperature12
W1
2 W
Max. permissible deviation from rated supply voltag
e±
10%
Across flats
P106 004E
1
(cartridge valve)
2
(coil nut)
PVPP connection

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520L0888 • Rev BB • Feb 2015
Service and Parts Manual PVG 100 Proportional Valves
Installation
Installation and technical
data for PVPE (solenoid
relief valve)
PVPE connection When installing the wire remember to
connect the built-in diode to the plug
pins.
Position Max. tightening torque
122 mm 5 Nm
[0.87 in
][
45 lbf·in]
236 mm 85 Nm
[1.42 in
][
750 lbf·in]
Max. operation pressure350 bar [5076 bar]
Max. coil surface temperature 155°C [311°F]
Rated voltage 12 V ––
__ 24 V –– __
Current consumtion 22°C (71,6°F) coil temperature1.55 A0.78 A
110°C (230°F) coil temperature1.00 A0.50 A
Power consumtion 22°C (71,6°F) coil temperature19
W1
9 W
110°C (230°F) coil temperature12
W1
2 W
Max. permissible deviation from rated supply voltag
e±
10%
Across flats
P106 288E
2 Nm
[17.5 lbf•in]
2.5 mm
2
(cartridge valve)
1
(coil nut)

12
Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
PVMR disassembly
P106 005
1. 2.
3.
4.
Installation

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520L0888 • Rev BB • Feb 2015
Service and Parts Manual PVG 100 Proportional Valves
PVMR/F assembly
P106 006
1.
2.
3. 4.
Y
X
X
X
X
Z
Z
XYZ
8 ± 0.5 Nm 15 ± 2 Nm 4 ± 1 Nm
Tightening torque [70 ± 4.5 lbf·in][135 ± 20 lbf·in][35 ± 9 lbf·in]
Width across flats
5 mm
36 mm
11 mm PVMF
19 mm PVMR
Tightening torques and
widths across ats
Installation

14
Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
Standard main spool
assembly for PVMR
E101 291E
3.
4. 8 Nm
[70 lbf·in]
8 Nm
[70 lbf·in]
12 mm
11 mm
1.
2.
12.5 mm
Note: Spools must be installed with LS holes
on ‘B’ port side of PVB.
Installation

15
520L0888 • Rev BB • Feb 2015
Service and Parts Manual PVG 100 Proportional Valves
Standard oat spool
assembly for PVMF
E101 290E
8 Nm
[70 lbf·in]
PA F
11 mm
8 Nm
[70 lbf·in]
12 mm
Note: Spools must be installed with LS holes
on ‘B’ port side of PVB.
Installation

16
Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
E101 303E
25
3
4
5
6
7
11
12
12
17
24
23 27
1
2
26
10
11
12
12
20
19
18 21
22
11
12
12
15
14
13
11
12
12
16
4 mm
20 Nm
[177 lbf•in] 6 mm
35 Nm
[310 lbf•in]
4 Nm
[35 lbf•in]
4 mm
41 mm
85 Nm
[750 lbf•in]
3 Nm
[25 lbf•in]
2.5 mm
4 Nm
[35 lbf•in]
6 mm
PVPF, open center pump
side module
Service parts

17
520L0888 • Rev BB • Feb 2015
Service and Parts Manual PVG 100 Proportional Valves
E101 304E
Type Description Code number
G1 thread UNF thread
PVPF 161B5110
161B5510
161B5112
161B5512
PVPF 161B5140
161B5540
161B5142
161B5542
Open center with pilot
supply for electrical
actuation, pilot gage
port, and facility for
pilot shut o
Open center with pilot
supply for electrical
actuation and pilot gage
port
12 bar
spring
20 bar
spring
12 bar
spring
20 bar
spring
Item Description Code No.
1 Spool, 12 bar 1 1 1 1
1 Spool, 20 bar 1 1 1 1
2 Orifice, 0.7 dia, M5 1 1 1 1 1 1 1 1
3 Washer, 19.3 x 34.0 x 3.0 [0.76 x 1.34 x 0.12] 1 1 1 1 1 1 1 1
4 Spring, 12 bar 1 1 1 1
4 Spring, 20 bar 1 1 1 1
5 Spring, 12 bar 1 1 1 1
5 Spring, 20 bar 1 1 1 1
6 O-ring, 33.3 x 2.4 [1.31 x 0.09] 1 1 1 1 1 1 1 1
7 Plug 1 1 1 1 1 1 1 1
10 Orifice, 0.7 dia, M8 x 1 1 1 1 1 1 1 1 1
11 Plug, G 1/4 thread 631X2036 4 4 4 4
11 Plug, 9/16-18 UNF thread 4 4 4 4
12 O-ring, 11.9 x 1.98 [0.47 x 0.08] 4 4 4 4
12 Washer, 13.5 x 17.5 x 1.5 [0.53 x 0.69 x 0.06] 4 4 4 4
13 LS relief valve 155L6485 1 1 1 1 1 1 1 1
14 Plastic cap 155L6377 1 1 1 1 1 1 1 1
15 Plastic plug w/O-ring (1 5/16-12 UNF thread) 156H7047 1 1 1 1
15 Plastic plug w/gasket (G1 thread) 633X0176 1 1 1 1
16 Plug assembly, w/O-ring (9/16-18 UNF thread) 30021-6A 4 4 4 4
17 Plastic plug w/gasket (9/16-18 UNF thread) 156H7043 1 1 1 1
17 Plastic plug w/gasket (G 1/4 thread) 633X0123 1 1 1 1
18 Cap plug assembly w/O-ring 1 1 1 1 1 1 1 1
19 Spring, PR 1 1 1 1 1 1 1 1
20 Spool, PR 1 1 1 1 1 1 1 1
21 Filter retainer (non-serviceable) 1 1 1 1 1 1 1 1
22 Filter, PR (non-serviceable) 1 1 1 1 1 1 1 1
23 Screw, pilot check valve (M10 x 1) 1 1 1 1
24 Spring, pilot check valve 1 1 1 1
25 Ball, pilot check valve (M6 steel) 1 1 1 1
26 Orifice, 0.4 dia (M10 x 1) 1 1 1 1 1 1 1 1
27 Plug assembly, w/seal (M12 x 1.5) 1 1 1 1 1 1 1 1
Seal kit (includes item 6 and 12) 11016012 1 1 1 1 1 1 1 1
LS relief valve service tool 155L6494
Service parts

18
Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
Service parts
E101 305E
85 Nm
[750 lbf•in]
17 mm
11
10
9
2 Nm
[17.5 lbf•in]
2.5 mm
8
7
6
5
4
3
2
136 mm
85 Nm
[750 lbf•in]
19
24 mm
35-40 Nm
[310-354 lbf•in]
18
16
20
17
15
13
14
1
13
12
5 Nm
[44.2 lbf•in]
PVPE, PVPD and pilot
shut-o (PVPP)

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520L0888 • Rev BB • Feb 2015
Service and Parts Manual PVG 100 Proportional Valves
Service parts
E101 306E
Type Code No.
12 volt 155G5052
24 volt 155G5054
PVPD Accessory plug (PVPF only) 155G5041
Electrical pilot shut-o valve 12 volt 161B5052
(PVPV or PVPF) 24 volt 161B5054
PVPE
PVPP
Extra electrical relief
(PVPF only)
Item Description Code No.
1 Electrical plug 155G5451 1 1 1 1
2 Electrical relief valve, 12 volt (item 3, 4, and 5 included) 155G5013 1
2 Electrical relief valve, 24 volt (item 3, 4, and 5 included) 155G5025 1
3 O-ring, 29.82 x 2.62 [1.18 x 0.10] 1 1
4 Back-up ring 27.0 x 2.0 [1.06 x 0.08] 1 1
5 O-ring, 26.7 x 1.78 [1.05 x 0.07] 1 1
6 Spring 1 1
7 Orifice, M5 x 0.5 dia. [ 0.2 x 0.02] 2 2
8 Spool 1 1
9 Plug (item 10 included) 1
10 O-ring, 30.3 x 2.4 [1.19 x 0.09] 1
11 Insert (item 9 and 10 included) 155G5041 1
12 Coil nut (item 13 included) 173800588 1 1
13 O-ring, 6-065 viton, 75D, 12 x 2 [0.47 x 0.08] 2 2
14 Coil, 12 volt, 22w DIN 171139819 1
14 Coil, 24 volt, 22w, DIN 171140019 1
15 Solenoid valve (item 12, 16, 17, 18, 19, and 20 included) 805339919 1 1
16 O-ring, 16.4 x 2.2 [0.65 x 0.09](3-908)D 1 1
17 Back-up ring, 8-014, 11.02 x 13.8 x 0.7 [0.43 x 0.54 x 0.03] 2 2
18 O-ring, 2-014 1 1
19 O-ring, 2-013 1 1
20 Back-up ring, 8-013 2 2
PVPE seal kit (includes item 3, 4, and 5) 155G8527 1 1
PVPP seal kit (includes item 10, 13, 16, 17, 18, 19, and 20) 35400321 1 1
PVPE, PVPD and pilot
shut-o (PVPP)

20
Service and Parts Manual PVG 100 Proportional Valves
520L0888 • Rev BB • Feb 2015
6 mm
35 ± 3 Nm
[310 ± 5 lbf•in]
11
12
16
15
14
13
Service tool
torque
20 Nm
[177 lbf•in]
17
16
16
25
24
23
6 mm
35 ± 3 Nm
[310 ± 5 lbf•in]
6 mm
35 ± 3 Nm
[310 ± 5 lbf•in]
17
13 mm
85 Nm
[750 lbf•in]
18
19
20
21
10
22
E101 334E
Service parts
PVPV, closed center pump
side module