Danfoss PVE 7 Series User manual

Service Manual
Electrohydraulic Actuators
PVE Series 7
powersolutions.danfoss.com

Revision history Table of revisions
Date Changed Rev
August 2017 First edition 0101
Service Manual
PVE Series 7
2 | ©Danfoss | August 2017 AX00000348en-US | 0101

Abbreviations Chart List of abbreviations for PVG/PVE...............................................................................................................................................4
Danfoss Literature Reference.......................................................................................................................................................5
Warnings PVE warnings......................................................................................................................................................................................6
General Information Introduction........................................................................................................................................................................................7
General instructions........................................................................................................................................................................ 8
Safety precautions............................................................................................................................................................................8
PVG with the PVE overview...........................................................................................................................................................9
Troubleshooting............................................................................................................................................................................... 9
Connector Overview.....................................................................................................................................................................10
Hydraulic Principle Variants....................................................................................................................................................... 12
Exchanging PVE Before replacing or dismounting a PVE.................................................................................................................................14
Dismounting of PVE......................................................................................................................................................................14
Mounting of Replacement..........................................................................................................................................................15
Test and use of PVG and Actuator........................................................................................................................................... 15
Returning Replaced Actuator for Customer Claims.......................................................................................................... 15
Service Manual
PVE Series 7
Contents
©Danfoss | August 2017 AX00000348en-US | 0101 | 3

List of abbreviations for PVG/PVE
Abbreviation Description
ASIC Application Specific Integrated Circuit - the part of the PVE where spool position is controled to
follow setpoint
ATEX Certificated for use in explosive environment
AVC Auxillery Valve Comand - ISOBUS/J1939 standard signal for valve control
AVCTO Auxillery Valve Comand Time Out - Fault monitoring setting
AVEF Auxillery Valve Estimated Flow - ISOBUS/J1939 standard signal for valve feedback
CAN Controller Area Network - Communication method used by PVED
CLC Closed Loop Circuit
CRC Cyclic Redundancy Check - Method for ensuring validity of data.
-DI PVE with Direction Indication
DM1 Diagnostic Message 1 - J1939 message informing about present fault
DM2 Diagnostic Message 2 - J1939 message informing about fault history
DM3 Diagnostic Message 3 - J1939 message clearing fault history
DSM Device State Machine. Deterministic description of system process
ECU Electronic Control Unit
EH Electrohydraulic
-F PVE for Float spool. Two variants: 4 pin with float at 75%. 6 pin with separate float.
FMEA Failure Mode Effect Analysis
ISOBUS Communication standard for CAN
J1939 Communication standard for CAN
LED Light Emitting Diode
LS Load Sensing
LVDT Linear Variable Differential Transducer - Position sensor
NC Normally Closed solenoid valve in PVE
NC-H Normally Closed standard solenoid valve in PVEH
NC-S Normally Closed solenoid valve Super in PVES
NO Normally Open solenoid valve in PVE
PLC Programmable Logical Circuit
PLUS+1®Trademark for Danfoss controllers and programming tool
POST Power On Self Test. Boot up evaluation for PVED
Pp Pilot Pressure. The oil gallery for PVE actuation
PVB Proportional Valve Basic module - valve slice
PVBS Proportional Valve Basic module Spool
PVBZ Proportional Valve Basic module Zero leakage
PVE Proportional Valve Electric actuator
PVEA PVE variant with 2-6 % hysteresis
PVED PVE variant Digital controlled via CAN communication
PVEH PVE variant with 4-9% Hysteresis
PVEM PVE variant with 25-35% hysteresis
PVEO PVE variant with ON/OFF actuation
PVEP PVE variant PWM controled
PVES PVE variant with 0-2% hysteresis
PVEU PVE variant with US 0-10V
PVG Proportional multi-section Valve Group
PVHC PV variant with High Current controlled valve actuator
Service Manual
PVE Series 7
Abbreviations Chart
4 | ©Danfoss | August 2017 AX00000348en-US | 0101

Abbreviation Description
PVM Proportional Valve Manual control with handle
PVP Proportional Valve Pump side module.Inlet
PVS Proportional Valve end plate
PVSK Proportional Valve end plate crane. Inlet module with Spool Control
PWM Pulse Width Modulation
S4 DJ Series 4 Digital J1939 service tool software for PVED-CC
SAE Society Automotive Engineering
-R PVE with Ramp function
-NP PVE with solenoid disable in Neutral Position
-SP PVE with Spool Position feedback
uC Microcontroller
uCSM Microcontroller State Machine
UDC Power supply Direct Current; also called Vbat for battery voltage
USSteering voltage for the PVE control; also called VS
Danfoss Literature Reference
Danfoss literature reference for PVG and PVE products
Title Type Order number
PVG 32 Proportional Valve Groups Service Manual 11039167
PVG 100 Proportional Valve Groups Service Manual 11048807
PVG 32 Proportional Valve Groups Technical Information 520L0344
PVG 100 Proportional Valve Groups Technical Information 520L0720
PVG 120 Proportional Valve Groups Technical Information 520L0356
PVE Series 7 Technical information BC00000XXXen-US0101
PVG 32 Metric ports Technical Information 11051935
Service Manual
PVE Series 7
Abbreviations Chart
©Danfoss | August 2017 AX00000348en-US | 0101 | 5

PVE warnings
W
Warning
Not applying to the Operational Conditions can compromise safety.
All brands and all types of directional control valves – including proportional valves – can fail and cause
serious damage. It is therefore important to analyze all aspects of the application. Because the
proportional valves are used in many different operation conditions and applications, the machine
builder/ system integrator alone is responsible for making the final selection of the products – and
assuring that all performance, safety and Warning requirements of the application are met.
A PVG with PVE can only perform according to description if conditions in this Technical Information are
met.
In particularly exposed applications, protection in the form of a shield is recommended.
When the PVE is in fault mode the quality of performance and validity of feedback is limited depending
on the fault type.
Error pins from more PVEs may not be connected. Inactive error pins are connected to ground and will
disable any active signal. Error pins are signal pins and can only supply very limited power consumption.
Deviation from recommended torque when mounting parts can harm performance and module.
Adjustment of the position transducer (LVDT) will influence calibration, and thereby also safety and
performance.
When replacing the PVE, the electrical and the hydraulic systems must be turned off and the oil pressure
released.
PVEA is not for use on PVG 100.
Hydraulic oil can cause both environmental damage and personal injury.
Module replacement can introduce contamination and errors to the system. It is important to keep the
work area clean and components should be handled with care.
After replacement of modules or cables wiring quality must be verified by a performance test.
By actuation at voltage below nominal PVG will have reduced performance.
The PVE is not designed for use with voltage outside nominal.
Obstacles for the Pilot oil can have direct influence on spool control.
Reduced pilot oil pressure will limit spool control.
Too high pilot oil pressure can harm the PVE.
Service Manual
PVE Series 7
Warnings
6 | ©Danfoss | August 2017 AX00000348en-US | 0101

Introduction
This manual includes information for trouble shooting and servicing the PVE actuators. The actuators are
used on PVG 32, PVG 100, PVG120 and some EH steerings. This manual does not cover the PVG in general
nor any steering.
PVE actuators
The PVE for PVG 32 and PVG 100 are the same, for PVG 120 includes a special interface plate, has another
LVDT-pin and allows larger spool travel. Service on the actuators is identical independent of valve size.
In general service on PVE is limited to exchange of O-rings and connectors or whole actuator.
Performing service, trouble shooting and repair may require removal of valve and valve parts from the
application. This can easily introduce misplaced parts and contamination and thereby thread
performance and safety. Following cleanliness requirements is a prerequisite for service.
For general description, specifications and operating parameters on PVG valves and actuators please see
the relevant Technical Information listed in reference list. Danfoss technical literature is available on
www.danfoss.com.
A worldwide network of Danfoss Global Service Partners is available for major repairs. Danfoss trains and
certifies Global Service Partners on a regular basis. You can locate your nearest Global Service Partner
using the distributor locator at www.danfoss.com.
W
Warning
Do not attempt to service PVG valves without build sheet specifications for reference.
Service Manual
PVE Series 7
General Information
©Danfoss | August 2017 AX00000348en-US | 0101 | 7

General instructions
Follow these general procedures when servicing PVG 32 valves:
Avoid injuries or material damage
Plan the process thoroughly. Block wheels and other moving parts to prevent undesired movement.
Secure against leakage of hydraulic fluid. Hydraulic fluid can cause contamination, cause burns due to
temperature and other injuries due to high pressure. Follow all instructions from machine builder.
Keep it clean
Cleanliness is the primary mean of assuring long lifetime for the application. Clean the outside of the
valve thoroughly before any disassembly. Cap ports and hoses when opening. Avoid contamination by
both dirt and chemical agents. Clean parts using a clean solvent wash and air dry.
Replace all O-rings and gaskets
Danfoss recommends inspection of O-rings and gaskets and replacement if wear or contamination
could be relevant. Dried out O-rings and gaskets must be replaced.
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others
from injury. Follow instructions from machine manufacture carefully. Read and include the warnings from
the relevant PVG literature in your work planing.
W
Warning
Ensure stable conditions
Manipulation on a mechanical, hydraulic and electrical system can potentially create dangerous
situations. Please ensure that all necessary precautions are taken to prevent dangerous situations.
W
Warning
Release hydraulic pressure in system
Shut down pump and release pressure in all work functions, in tank and pilot pressure if not released by
previous operations
W
Warning
Disengage electrical system
Disengage power supply and system control. If relevant for application, disengage system output e.g.
error pin, direction indicator.
Service Manual
PVE Series 7
General Information
8 | ©Danfoss | August 2017 AX00000348en-US | 0101

PVG with the PVE overview
The PVG is a sectional spool valve stack with up to 12 individually controlled proportional valves. The PVG
with the PVE can be operated as single valves or several valves in cooperation. The oil flow out of the
work section (A- or B-port) can be controlled by a combination of the following:
•PVE controlling the spool position using pilot oil pressure.
•A handle (PVM) in mechanical interface with the spool.
The analog PVE Series 7 is an electro-hydraulic actuator used to control a single work section of a PVG
proportional valve group. The PVE Series 7 actuator program includes variants with different
performance levels and features for PVG 32/100/120/128/256.
The actuator positions the main spool in a PVG work section in order to control either the flow or the
pressure of the oil distributed to/from the work function. The control signal to the actuator is an analog
voltage signal, enabling the user to operate the work function remotely by means of a joystick, a
controller or the like.
The electro-hydraulic solenoid valve bridge of the actuator is available in different designs, utilizing
different regulation principles, depending on performance variant. The actuator positions the main spool
by distributing pilot oil pressure to either side of it, pressurizing one side by pilot pressure while relieving
the opposite side to tank and vice versa. All proportional actuators feature a closed-loop spool control
and continuous fault monitoring.
The analog PVE Series 7 actuator program features five different main hydraulic principle variants
(PVEO/M/A/H/S). The different hydraulic principles combined with the different solenoid valve regulation
principles determine whether the actuator controls the spool proportionally according to a demand
signal or ON/OFF according to a voltage signal.
Valve section - standard mounted - seen from PVP with naming
Troubleshooting
The Service Manuals for PVG 32 and PVG 100 have a thorough description of system troubleshooting and
parts troubleshooting. Please look for descriptions there before starting with the actuator. The actuator is
an electrohydraulic subsystem used for moving the spool and thereby opens the valve for work flow.
Service Manual
PVE Series 7
General Information
©Danfoss | August 2017 AX00000348en-US | 0101 | 9

Connector Overview
PVEO/PVEO-R/PVEO-HP
Connector Pin 1 Pin 2 Pin 3 Pin 4
1x4 AMP Udc_A Udc_B GND GND
1x4 DEU Udc_A GND GND Udc_B
1x4 DIN Udc_A Udc_B GND
PVEO-DI
Connector Pin 1 Pin 2 Pin 3 Pin 4
2x4 AMP (A) Udc_A Udc_B GND GND
2x4 AMP (B) DI-B DI-A GND Udc2
PVEM
Connector Pin 1 Pin 2 Pin 3 Pin 4
1x4 DIN Udc Us Error GND
PVEA/PVEH/PVES
Connector Pin 1 Pin 2 Pin 3 Pin 4
1x4 AMP Us Udc GND Error
1x4 DEU Us Error GND Udc
1x4 DIN Udc Us Error GND
PVEA-DI/PVEH-DI
Connector Pin 1 Pin 2 Pin 3 Pin 4
2x4 AMP (A) Us Udc GND Error
2x4 AMP (B) DI-A DI-B GND Udc2
2x4 DEU (A) Us Error GND Udc
2x4 DEU (B) Udc2GND DI-A DI-B
PVEH-FLA
Connector Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6
1x6 AMP Us Udc GND Error Float
1x6 DEU Us Error Float GND Udc
PVEH-SP/PVES-SP
Connector Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6
1x6 DEU Us Error SP GND Udc
Service Manual
PVE Series 7
General Information
10 | ©Danfoss | August 2017 AX00000348en-US | 0101

Connector diagrams
1x4 DEUTSCH
23
4
1
1x6 DEUTSCH
1
2
3 4
5
6
2x4 DEUTSCH
3
4
1
2
1
23
4
A
B
1x4 DIN
12
3
4
1x4 AMP
2418
1
2
3
4
1x6 AMP
1
2
34
5
6
2x4 AMP
1
2
3
4
Service Manual
PVE Series 7
General Information
©Danfoss | August 2017 AX00000348en-US | 0101 | 11

Hydraulic Principle Variants
Principle of PVEO/PVEO-R/PVEO-DI
21 0
Pp
LVDT
LED Circuit /
Microcontroller
Power
Supply
PVEO-DI
A
B
DI_B
DI_A
LED
Udc
Ramp Ramp
SV1 SV2
P109126
Principle of PVEM
21 0
Pp
LVDT
SV2SV1
Micro-
controller
Power
Supply
UDC
US
Error
LED
P109132
Principle PVEA
21 0
Pp
Micro-
controller
Power
Supply
NP
DI_B
DI_A
Udc
LED
Error
Us
Udc
2
Special
Features
NC1 NC3
LVDT
P109147
Service Manual
PVE Series 7
General Information
12 | ©Danfoss | August 2017 AX00000348en-US | 0101

Principle of PVEH
21 0
Pp
Micro-
controller
Power
Supply
US
Special
Features SP
NP
Uf
DI_B
DI_A
Udc2
LED
Error
Udc
NC1 NC3
NO4
NO2
LVDT
P109148
Principle of PVES
21 0
Pp
Micro-
controller
Power
Supply
Special
Features SP
LED
Error
Us
Udc
NC1 NC3
NO2 NO4
LVDT
P109149
Troubleshooting actuator
For warranty claims please verify and describe below points before replacing actuator.
•Function of external parts
‒Spool can move as expected when activated by PVM
‒Pilot pressure is available
‒Control signal can activate other PVE/PVHC
‒Cabling is undamaged
‒Connectors are with sealing and dry
•Function of PVE
‒Failure is temporary/continues
‒Failure is in one direction (A or B) or both
‒Visible damage
Service Manual
PVE Series 7
General Information
©Danfoss | August 2017 AX00000348en-US | 0101 | 13

These guidelines are only meant to point out issues that could be related to the application, the PVG and
its actuator. Danfoss can and will not give directives how work has to be planed and supervised.
Before replacing or dismounting a PVE
1. Ensure that the actuator has to be dismounted. Follow the trouble shooting procedure to make sure
that the failure is not elsewhere in the application. See Service Manual for PVG32 and PVG100.
2. Clean surroundings on PVG for dirt and rust/oxidations; and do not use cleaning agents or methods
that require higher IP than the actuator supports.
3. Have a clean area to put new PVE/PVHC before mounting.
4. Have a clean area to put old PVE/PVHC before eventually returning for investigation.
5. Have the right tools at hand.
6. Ensure that spare part is the correct actuator .
7. Unpack replacing actuator:
a) If actuator has LVDT avoid mishandling and bending of it
b) Ensure all O-rings are in place
c) Ensure new bolts are present
d) Ensure presence of eventually electrical connector sealing
e) Eventually clean off excessive oil with a soft tissue. PVE must still be coated with a thin oil film
f) Keep actuator protected from a pollution during the whole process. Keep in a bag.
Mounting of PVE variants
5 [0.2]
8 ± 0.5 N·m
[70 ± 4.4 lbf·in]
PVEO/M/A Series 7
5 [0.2]
8 ± 0.5 N·m
[70 ± 4.4 lbf·in]
PVEH/S Series 7
P109120
Dismounting of PVE
1. Remove connector(s) from PVE:
a) Pull connector, not cable.
b) Verify if cable and connectors can be reused or must be replaced e.g. isolation, lock.
2. Loosen and unscrew bolts counter clockwise. Be aware of leaking oil.
3. Remove PVE/PVHC carefully:
a) Don’t introduce pollution to PVB nor actuator. Marked areas are especial sensible to pollution
“cover”.
b) Ensure O-rings are removed with actuator.
c) Place removed actuator safe best in a bag.
4. Eventually clean PVB carefully with a soft tissue to have clean interface for replacing actuator.
Service Manual
PVE Series 7
Exchanging PVE
14 | ©Danfoss | August 2017 AX00000348en-US | 0101

Mounting of Replacement
1. Avoid contamination - also oil in connectors.
2. Avoid harming LVDT pin.
3. Depending on PVB – actuator orientation place one or all bolts in actuator bolt holes.
4. Reassure that O-rings are in place on actuator.
5. Place actuator on PVB and screw bolts lose and clockwise.
6. Tighten bolts to torque indicated in instruction.
7. Connect wiring.
Test and use of PVG and Actuator
After replacement of actuator the system must be tested after manufactures guidelines.
After service the PVG must be tested according to manufactures guidelines. Ensure that safety functions
and performance apply to demands.
Before restart bleed system. PVG can be bleed through PVM. Let application run for In worst cases air
must be washed out by oil in up to 5 minutes activation.
Returning Replaced Actuator for Customer Claims
If replaced actuator is returned to Danfoss for analysis description of malfunction and application must
be submitted too. See form in section “returning claims”.
Service Manual
PVE Series 7
Exchanging PVE
©Danfoss | August 2017 AX00000348en-US | 0101 | 15

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
that excel in the harsh operating conditions of the mobile off-highway market. Building on
our extensive applications expertise, we work closely with our customers to ensure
exceptional performance for a broad range of off-highway vehicles.
We help OEMs around the world speed up system development, reduce costs and bring
vehicles to market faster.
Danfoss – Your Strongest Partner in Mobile Hydraulics.
Go to www.powersolutions.danfoss.com for further product information.
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
with an extensive network of Global Service Partners, we also provide comprehensive global
service for all of our components.
Please contact the Danfoss Power Solution representative nearest you.
Local address:
Danfoss
Power Solutions GmbH & Co. OHG
Krokamp 35
D-24539 Neumünster, Germany
Phone: [phone]
Danfoss
Power Solutions ApS
Nordborgvej 81
DK-6430 Nordborg, Denmark
Phone: [phone]
Danfoss
Power Solutions (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: [phone]
Danfoss
Power Solutions Trading
(Shanghai) Co., Ltd.
Building #22, No. 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: [phone]
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.
©Danfoss | August 2017 AX00000348en-US | 0101
Products we offer:
•Bent Axis Motors
•Closed Circuit Axial Piston
Pumps and Motors
•Displays
•Electrohydraulic Power
Steering
•Electrohydraulics
•Hydraulic Power Steering
•Integrated Systems
•Joysticks and Control
Handles
•Microcontrollers and
Software
•Open Circuit Axial Piston
Pumps
•Orbital Motors
•PLUS+1®GUIDE
•Proportional Valves
•Sensors
•Steering
•Transit Mixer Drives
Comatrol
www.comatrol.com
Turolla
www.turollaocg.com
Hydro-Gear
www.hydro-gear.com
Daikin-Sauer-Danfoss
www.daikin-sauer-danfoss.com