Danfoss CDS Directional Control Valve User guide

CDS Directional
Control Valve

Assembly and Test
Manual

2

520L0924 • October 2005

CDS Directional Control Valve Assembly and Testing Manual

© 2005 Sauer-Danfoss. All rights reserved. Printed in U.S.A.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products
already ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are

trademarks of the Sauer-Danfoss Group. Detroit Diesel®, Cummins®, and Caterpillar® trademarks are properties
of their respective owners.

Front cover illustrations: F101 489, F301 112, P104 394

ORGANIZATION AND
HEADINGS

To help you quickly find information in this manual, the material is divided into sections,
topics, subtopics, and details, with descriptive headings set in red type. Section titles
appear at the top of every page in large red type. Topic headings appear in the left
hand column in BOLD RED CAPITAL LETTERS. Subtopic headings appear in the body
text in bold red type and detail headings in italic red type.

References (example: See Topic xyz, page XX) to sections, headings, or other publications are
also formatted in red italic type. In Portable Document Format (PDF) files, these references
represent clickable hyperlinks that jump to the corresponding document pages.

Tables, illustrations, and graphics in this manual are identified by titles set in

blue italic

type above each item. Complementary information such as notes, captions, and drawing

annotations are also set in blue type.

References (example: See

Illustration abc, page YY) to tables, illustrations, and graphics

are also formatted in blue italic type. In PDF files, these references represent clickable
hyperlinks that jump to the corresponding document pages.

Defined terms and acronyms are set in bold black

type in the text that defines or

introduces them. Thereafter, the terms and acronyms receive no special formatting.

Black italic

type is used in the text to emphasize important information, or to set-off
words and terms used in an unconventional manner or alternative context. Red and blue
italics represent hyperlinked text in the PDF version of this document (see above).

An indented

Table of Contents (TOC) appears on the next page. Tables and illustrations
in the TOC set in blue type. In the PDF version of this document, the TOC entries are
hyperlinked to the pages where they appear.

TABLES, ILLUSTRATIONS,
AND COMPLEMENTARY
INFORMATION

SPECIAL TEXT
FORMATTING

TABLE OF CONTENTS

Using this manual

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520L0924 • October 2005

INTRODUCTION

ASSEMBLY

TESTING

TROUBLESHOOTING

APPENDIX A

CDS Directional Control Valve Assembly and Testing Manual

Contents

Overview ...........................................................................................................................................................4

General instructions ...................................................................................................................................... 4

Safety precautions ......................................................................................................................................... 5

Unintended machine movement ....................................................................................................... 5

Flammable cleaning solvents ...............................................................................................................5

Fluid under pressure ................................................................................................................................ 5

Personal safety ........................................................................................................................................... 5

Symbols used in Sauer-Danfoss literature .............................................................................................6

Required tools .................................................................................................................................................6

Assembly instructions ..................................................................................................................................

7

Centering types ...............................................................................................................................................9

Spring centered assembly (A) ..............................................................................................................9

Three position detent assembly (B) .................................................................................................10

Spring/detent detent assembies (C,D&E) ......................................................................................11

Spring center/float detent assembly (J) .........................................................................................13

Hydraulic kickout (F) ..............................................................................................................................14

Spring center assembly (G, H, I) ..........................................................................................................14

Auxiliary valves ..............................................................................................................................................15

Load check ......................................................................................................................................................16

Handle assembly ..........................................................................................................................................17

Joystick assembly .........................................................................................................................................18

Alternate joystick assembly ......................................................................................................................19

Cable assembly .............................................................................................................................................20

Oil and test conditions ...............................................................................................................................22

Adjusting pressure settings ......................................................................................................................

22

Main relief valve ......................................................................................................................................22

Work port relief valve ............................................................................................................................22

Adjusting main/port relief valves ......................................................................................................22

Leakage testing .............................................................................................................................................23

Work port leakage ..................................................................................................................................23

Load check leakage ................................................................................................................................23

Function testing ............................................................................................................................................24

Spring Center Function .......................................................................................................................24

Detent Functions ....................................................................................................................................24

Float Functions ........................................................................................................................................25

Pneumatic Function ..............................................................................................................................25

Hydraulic Function .................................................................................................................................25

Solenoid Function .................................................................................................................................26

Three Way Spools ....................................................................................................................................26

Backpressure test .........................................................................................................................................26

The valve leaks ...............................................................................................................................................

28

It still leaks .......................................................................................................................................................28

Sticky spool ....................................................................................................................................................29

Relief doesn’t work .......................................................................................................................................29

Cable binds .....................................................................................................................................................29

Appendix A Testing certification form ..................................................................................................

30

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520L0924 • October 2005

Follow these general procedures when assembling CDS stack valves.

e Keep it clean

Cleanliness is a primary means of assuring satisfactory valve life, on either new or
repaired units. Clean the outside of the valve thoroughly before assembly. Take care to
avoid contamination of the system ports. Cleaning parts by using a clean solvent wash
and air drying is usually adequate.

As with any precision equipment, all parts must be kept free of foreign materials and
chemicals. Protect all exposed sealing surfaces and open cavities from damage and
foreign material. If left unattended, cover the valve with a protective layer of plastic.

l Lubricate moving parts

During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that
these parts will be lubricated during start-up.

d Lubricate all O-rings and gaskets

Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. If the stack valve
is being repaired, it is recommended that all O-rings be replaced..

GENERAL INSTRUCTIONS

CDS Directional Control Valve Assembly and Testing Manual

Introduction

This manual provides information and procedures for the assembly of a new CDS valve
group using the following guidelines:

The specification sheet (CDS build tool and CDS order form) is compiled by the
distributor and assigned a number provided by Sauer-Danfoss. The order form is then
sent to Sauer Danfoss (preferably electronically [FAX]) and reviewed and approved by
the Sauer-Danfoss Technical Support Team (TST) or customer service (CDS) assigned
personnel. The specification sheet will then be logged into a master file. Once it is
determind that the distributor wants S-D to start providing this assembly, a Sauer­Danfoss part number will be assigned.

After final testing, the test certification, (Appendix A), is to be completed by the
assembly/testing personnel. A copy of the certification must be sent to the TST at Sauer­Danfoss, Easley, SC.

Before, during and after the assembly/disassembly of new CDS groups, absolute
cleanliness and care must be observed with regard to internal and external parts of the
units concerned. Use non-volatile, petroleum based solutions for cleaning valves and/or
modules. Replace all parts considered likely to cause malfunction during subsequent
testing and report nonconforming product to Sauer-Danfoss (TST ). Replace all loose
O-rings (without exceptions) with new O-rings. Lubricate all moving parts with hydraulic
oil before assembly. Lubricate all O-rings with petroleum jelly. Lubricate all detent and
spring centered accessories with LUBRIPLATE 730-1 or equvaliant.

Refer to this manual and the CDS Specification sheet for module designations, item
numbers, spare parts numbers, tightening torques, etc., whether assembling new groups
or making repairs.

Refer to Directional Control Valves Technical Information Manual

520L0564 for more

detailed information including order codes and specifications.

OVERVIEW

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520L0924 • October 2005

CDS Directional Control Valve Assembly and Testing Manual

Introduction

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.

Unintended machine movement
W Warning

Unintended movement of the machine or mechanism may cause injury to the technician
or bystanders. To protect against unintended movement, secure the machine or disable /
disconnect the mechanism while servicing.

Flammable cleaning solvents
W Warning

Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning
solvents in an area where a source of ignition may be present.

Fluid under pressure
W Warning

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.

Personal safety
W Warning

Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.

SAFETY PRECAUTIONS

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520L0924 • October 2005

 WARNING may result in injury

 CAUTION may result in damage to

product or property

 Reusable part

 Non-reusable part, use a new part

 Non-removable item

 Option – either part may exist

 Superseded – parts are not

interchangeable

 Measurement required

 Flatness specification

 Parallelism specification

 External hex head

 Internal hex head

 Torx head

 O-ring boss port

 Tip, helpful suggestion

 Lubricate with hydraulic fluid

 Apply grease/petroleum jelly

 Apply locking compound

 Inspect for wear or damage

 Clean area or part

 Be careful not to scratch or damage

 Note correct orientation

 Mark orientation for reinstallation

 Torque specification

 Press in – press fit

 Pull out with tool – press fit

 Cover splines with installation

sleeve

 Pressure measurement/gauge

location or specification

SYMBOLS USED IN
SAUER-DANFOSS
LITERATURE

The symbols above appear in the illustrations and text of this manual. They are intended
to communicate helpful information at the point where it is most useful to the reader.
In most instances, the appearance of the symbol itself denotes its meaning. The legend
above defines each symbol and explains its purpose.

CDS Directional Control Valve Assembly and Testing Manual

Introduction

REQUIRED TOOLS The following tools are required to build a CDS control valve :

Hand tools:
Hex head wrench: 3/32, 1/8, 5/32, 1/4
Sockets: 3/8 deep well, 11 mm, 13 mm, 17 mm, 1 inch, 22 mm, 32 mm
Phillips and flat head screw driver
Torque wrench: 3/8 drive 0-68 N•m [0-50 lbf•ft].

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520L0924 • October 2005

CDS Directional Control Valve Assembly and Testing Manual

Assembly

ASSEMBLY
INSTRUCTIONS

The valve is to be assembled in accordance with the CDS stack valve order form.

Install inlet section first

The assembly sequence for CDS stack valve groups is as follows :

1. Ensure that all parts required, according to the completed CDS stack valve order
form are present. Unpack and inspect all parts for damage and cleanliness. Ensure
that all parts are free of nicks, burrs, contamination etc.

4 Install shims between each section,

one per tie rod.

This will ensure that the O-rings do not fall out during assembly

The first spool listed in model number is closest to the inlet section.

Install shims between each section

Install shims between each section
including Inlet and Outlet sections.

6. Install the basic valve section
module(s) indicated on the order
form against the inlet section.
Ensure that the machined surface
of the next section faces the O-rings
of the previous section.

Following assembly steps include installation of optional relief valves and optional
control components.

2. Install a nut and lock washer on one
end of each tie rod. Guide tie rods
through holes in each section (inlet
section first).

3. Place all lubricated O-rings in their
respective grooves in the different
modules before installing them.

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520L0924 • October 2005

CDS Directional Control Valve Assembly and Testing Manual

Assembly

7. Install the outlet section against the
last basic valve section.

8. Install lockwashers and nuts on end

of tie rods.

Install the lock washers and nuts hand
tight so the sections can’t separate and
allow the O-rings to fall out of place.

Install outlet section

11. Check each spool to ensure free movement of all sections. Any binding or sticking
in spools is unacceptable. If binding/sticky spools are present, disassemble the stack
and inspect for cause. Replace parts as required.

Spool movement will have a slight drag from the O-rings. Be careful not to shift the spool
end past the O-rings. Shifting spool end past the O-rings may damage the O-rings.

12. The spools are pre-installed into the spool bores of each valve section at the factory.
Each spool is matched to its housing. Do not interchange spools. Inter-changing
a spool from one section to another, may cause spool to bind and/or create high
internal spool leakage.

13. Install the specified option (plug
or relief valve) to the inlet section.
Torque to 27-39 N•m [20-25 lbf•ft]

Install plug/relief valve in inlet section

9. Lay the stack down on its mounting
feet. Adjust washers and nuts so
tie rods stick out equal distance on
either side of valve.

10. Tighten tie rod nuts incrementaly in
staggered order.

Tie rod nut torque:

• CDS 60 is 16-18 N•m [13-15 lbf•ft] ,

• CDS 100 is 25-27 N•m 18-20 [lbf•ft]

using a 1/2 inch socket.

Torque tie rods

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520L0924 • October 2005

CDS Directional Control Valve Assembly and Testing Manual

Assembly

CENTERING TYPES Assemble the spring/detent assemblies to the valve as specified in the order form. The

stem(s) for each assembly must have Liquid Lock ThreadsTM or equivalent applied. For
CDS 60 tighten the stem(s) to a torque of 2.7-4.0 N•m [2-3 lbf•ft] using a 11mm socket.
For CDS 100 tighten the stem(s) to a torque of 4.0-5.4 N•m [3-4 lbf•ft] using a 13mm
socket.

Spring/detent assemblies1. Install the stem and spring assembly

on the spool using Liquid Lock
ThreadsTM or equivalent. For CDS
60 tighten the stem(s) to a torque
of 2.7-4.0 N•m [2-3 lbf•ft] using a
11mm socket. For CDS 100 tighten
the stem(s) to a torque of 4.0-5.4 N•m
[3-4 lbf•ft] using a 13mm socket.

2. Lubricate the spring assembly with
Lubriplate 730-1TM or equivalent.

3. Install the end cap over the spring
package. Apply Liquid Lock Threads

TM

or equivalent and install the two
(2) screws and washers using the
appropriate screw driver.

Screw torque:

• CDS 60 and CDS 100 2.7-4.0 N•m [2-3

lbf•ft].

Lubricate spring assembly

Install endcap over spring assembly

For loose sections,

complete assembly with

section clamped in a

protective jawed vice

before adding to stack..

Spring centered assembly (A)

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520L0924 • October 2005

CDS Directional Control Valve Assembly and Testing Manual

Assembly

1. Install stem on spool using using
Liquid Lock ThreadsTM or equivalent.
For CDS 60 tighten the stem(s) to
a torque of 2.7-4.0 N•m [2-3 lbf•ft]
using a 11mm socket. For CDS 100
tighten the stem(s) to a torque of

4.0-5.4 N•m [3-4 lbf•ft] using a 13mm
socket.

2. Fasten cap to spool with two screws
and washers. Using a 5/32 hex driver,
torque screws to 5.5-8.2 N•m [4-6
lbf•ft].

Install detent assembly

Install spring in detent assembly

Install cover in detent assembly

3 Lubricate the steel balls and

spring with LUBRIPLATE 730-1TM or
equivalent.

4. Install one ball and the spring into
the holes of the end cap.

5. Install second ball on other end of
spring.

6 Compress the balls against the

spring evenly and slip the sleeve
over the end.

Three position detent assembly (B)CENTERING TYPES

(continued)